9MPT 9MPV - Carrier...Printed in U.S.A. LP1 9/4/2001 440 01 2010 04 2--Stage Gas Furnaces 9MPT-- Multispeed PSC Blower Motor 9MPV-- Variable Speed Motor *Denotes Brand MODEL NUMBER

Manufactured by:

International Comfort Products Corporation (USA)Lewisburg, TN USA 37091

DANGER!Electric Shock Hazard.

Turn Off All Power BeforeServicing.

Failure to do so can resultin death, personal injuryand/or property damage.

Fire or Explosion hazard.This furnace is not designed for use in mobilehomes, trailers or recreational vehicles.Such use could result in death, bodily injuryand/or property damage.

!

Four Position 2-- Stage Condensing Gas Furnace

Printed in U.S.A. LP1 9/4/2001 440 01 2010 04

*9MPT*9MPV

SAFETY REQUIREMENTS

Recognize safety information. This is the safety--alert symbol ! . When you see this symbol on the furnace and in instructions ormanuals be alert to the potential for personal injury.

Understand the signal words DANGER, WARNING, or CAUTION. These words are used with the safety--alert symbol. DANGERidentifies the most serious hazards, those thatwill result in severe personal injury or death. WARNING signifies a hazard that couldresult in personal injury or death. CAUTION is used to identify unsafe practices that could result inminor personal injury or product andproperty damage.

Installing and servicing heating equipment can be hazardous due to gas and electrical components. Only trainedand qualified person-nel should install, repair, or service heating equipment.

Untrained service personnel can perform basic maintenance functions such as cleaning and replacing air filters. All other operationsmust be performed by trained service personnel. When working on heating equipment, observe precautions in the literature, on tags,and on labels attached to or shipped with the unit and other safety precautions that may apply.

Followall safety codes. In theUnitedStates, followall safety codes including the current editionNational FuelGasCode (NFGC)NFPANo. 54/ANSIZ223.1. In Canada, refer to the current edition of the National Standard Canada CAN/CGA--B149.1-- and .2--M91NaturalGasandPropane InstallationCodes (NSCNGPIC). Wear safetyglassesandwork gloves. Have fireextinguisheravailableduringstart--up and adjustment procedures and service calls.

These instructions cover minimum requirements and conform to existing national standards and safety codes. In some instances,these instructions exceed certain local codes and ordinances, especially those that may not have kept up with changing residentialconstruction practices. We requre these instructions as a minimum for a safe installation.

Table of Contents

1. Safe Installation Requirements 4. . . . . . . . . . . . . . . . .2. Installation 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3. Combustion & Ventilation Air 8. . . . . . . . . . . . . . . . . .4. Vent & Combustion Air Piping 10. . . . . . . . . . . . . . . .5. Gas Supply and Piping 20. . . . . . . . . . . . . . . . . . . . . .6. Electrical Wiring 24. . . . . . . . . . . . . . . . . . . . . . . . . . .

7. Ductwork and Filter (Upflow/Horizontal) 25. . . . . . . . .8. Checks and Adjustments 29. . . . . . . . . . . . . . . . . . . .9. Furnace Maintenance 31. . . . . . . . . . . . . . . . . . . . . . .10. Sequence of Operation & Diagnostics 31. . . . . . . . . .11. Concentric Vent Termination 37. . . . . . . . . . . . . . . . .

Printed in U.S.A. LP1 9/4/2001 440 01 2010 04

2--Stage Gas Furnaces*9MPT -- Multispeed PSC Blower Motor

*9MPV -- Variable Speed Motor*Denotes Brand

MODEL NUMBER IDENTIFICATION GUIDE

* 9 M P T 0 75 B 1 2 A 1Brand Engineering Rev.

Brand Identifier Denotes minor changes

8 = Non--Condensing, 80+% Gas Furnace Marketing Digit

9 = Condensing, 90+% Gas Furnace Denotes minor change

Installation Configuration

UP = Upflow Cooling Airflow

DN = Downflow 08 = 800 CFM

UH = Upflow/Horizontal 12 = 1200 CFM

HZ = Horizontal 14 = 1400 CFM

DH = Downflow/Horizontal 16 = 1600 CFM

MP = Multiposition, Upflow/Downflow/Horizontal 20 = 2000 CFM

Cabinet Width

Major Design Feature B = 15.5� Wide

1 = One (Single) Pipe N = Single Stage F = 19.1� Wide

2 = Two Pipe P = PVC Vent J = 22.8� Wide

D = 1 or 2 Pipe T = Two Stage L = 24.5� Wide

L = Low NOx V = Variable Speed Input (Nominal MBTUH)

* Denotes Brand

3440 01 2010 04

START--UP CHECK SHEETFor 90+ Furnace

(Keep this page for future reference)

Dealer Name:

Address: Business Card Here

City, State(Province), Zip or Postal Code:

Phone:

Owner Name:

Address:

City, State(Province), Zip or Postal Code:

Model Number:

Serial Number:

Type of Gas: Natural: LP:

Which blower speed tap is used?

High Fire Low Fire or (Cooling)

Temperature of Supply Air: High Fire (�F) or (�C)

Low Fire (�F) or (�C)

Temperature of Return Air: (�F) or (�C)

Temp. Rise Hi Fire (Supply -- Return ): (�F) or (�C)

Lo Fire (Supply -- Return ): (�F) or (�C)

Filter Type and Size:

Fan �Time ON� Setting:

Fan �Time OFF� Setting:

Manual Gas Shut--Off Upstream

of Furnace/Drip--Leg? YES NO

Condensate Drain Connected? YES NO

Condensate Drain Trapped? YES NO

Transition Pressure switch hose relocated for U/D/H

Application? YES NO

Blower Speed Checked? YES NO

All Electrical Connections Tight? YES NO

Gas Valve OK? YES NO

Measured Line Pressure When Firing Unit:

CalculatedFiringRate:(SeeChecks andAdjustmentsSec-

tion). (Lo) & (Hi)

Temperature Rise (supply--return temperature):(�F)

Measured Manifold Gas Pressure: (Lo) & (Hi)

Static Pressure (Ducts): Supply Air Return

Date of Start--Up:

CO ?

CO2 ?

Dealer Comments:

4 440 01 2010 04

1. Safe Installation Requirements

Installation or repairs made by unqualifiedpersons can result in hazards to you and others.InstallationMUST conformwith local codes or, inthe absence of local codes, with codes of allgovernmental authorities having jurisdiction.

The information contained in this manual isintended for use by a qualified service technicianwho is experienced in such work, who is familiarwith all precautions and safety proceduresrequired in such work and is equipped with theproper tools and test instruments.

Failure to carefully read and follow all instruc-tions in this manual can result in furnacemalfunction, death, personal injury and/orproperty damage.

!

NOTE: This furnace is design certified by the Canadian Stan-dards Association (CSA) for installation in the United States andCanada. Refer to the appropriate codes, along with Figure 1 orFigure 2 and this manual, for proper installation.

� This furnace is NOT approved for installation inmobile homes, trailers or recreation vehicles.

� Do NOT use this furnace as a construction heater or toheat a building that is under construction.

� Use only the Type of gas approved for this furnace (seeRating Plate on unit). Overfiring will result in failure ofheat exchanger and cause dangerous operation. (Fur-naces can be converted to L.P. gas with approved kit.)

� Do NOT use open flame to test for gas leak.

� Ensure adequate combustion and ventilation air is pro-vided to the furnace.

� Seal around supply and return air ducts.

� Thevent systemMUSTbechecked todetermine that it isthe correct type and size.

� Install correct filter type and size.

� Unit MUST be installed so electrical components areprotected from direct contact with water.

NOTE: It is the personal responsibility and obligation of the enduser to contact aqualified installer to ensure that the installation isadequate and conforms to governing codes and ordinances.

Safety Rules

Your unit is built to provide many years of safe and dependableservice provided it is properly installed andmaintained.However,abuse and/or improper use can shorten the life of the unit andcreate hazards for you, the owner.

A. The U.S. Consumer Product Safety Commission recom-mends that users of gas--burningappliances install carbonmonoxide detectors. There can be various sources of car-bonmonoxide in a building or dwelling. The sources couldbe gas--fired clothes dryers, gas cooking stoves, water

heaters, furnaces, gas--fired fireplaces, wood fireplaces,and several other items. Carbonmonoxide can cause seri-ous bodily injury and/or death. Therefore, to help alertpeople of potentially dangerous carbon monoxide levels,you should havecarbonmonoxidedetectors listedby ana-tionally recognized agency (e.g. Underwriters Laborato-ries or International Approval Services) installed andmaintained in the building or dwelling (see Note below).Carbon monoxide or �CO� is a colorless and odorless gasproduced when fuel is not burned completely or when theflame does not receive sufficient oxygen.

B. There can be numerous sources of fire or smoke in a build-ing or dwelling. Fire or smoke can cause serious bodily in-jury, death, and/or property damage. Therefore, in order toalert people of potentially dangerous fire or smoke, youshould have fire and smoke detectors listed by Underwrit-ers Laboratories installed andmaintained in the building ordwelling (see Note below).

Note: The manufacturer of your furnace does not test any de-tectors andmakesno representations regardinganybrandor type of detector.

C. To ensure safe and efficient operation of your unit, youshould do the the following:

1. Thoroughly read this manual and labels on the unit.This will help you understand how your unit operates andthe hazards involved with gas and electricity.

2. Do not use this unit if any part has been under water.Immediately call a qualified service technician to inspectthe unit and to replace any part of the control system andany gas control which has been under water.

3. Never obstruct the vent grilles, or any ducts that pro-vide air to the unit. Air must be provided for proper com-bustion and ventilation of flue gases.

Freezing Temperatures and Your Structure

Freeze warning.

Turn off water system.

If your unit remains shut off during cold weatherthe water pipes could freeze and burst, resultingin serious water damage.

!

Your unit is equippedwith safety devices thatmay keep it fromop-erating if sensorsdetect abnormal conditions suchascloggedex-haust flues.

If your unit remains shut off during cold weather the water pipescould freeze and burst, resulting in serious water damage.

If the structurewill be unattended during coldweather you shouldtake these precautions.1. Turn off main supply water into the structure and drain the

water lines if possible. Open faucets in appropriate areas.2. Have someone check the structure frequently during cold

weather to make sure it is warm enough to prevent pipesfrom freezing. Suggest they call qualified service agency, ifrequired.

Winter ShutdownIf you go away during thewintermonths anddo not leave the heaton in your home, the plastic transition box and the condensate

5440 01 2010 04

trap on the furnace must be protected from freeze damage.(SeeFigure 8 trough Figure 11)

1. Disconnect the 5/8�OD rubber hose from the vent drain fit-ting that is located downstream of the combustion blower.Insert a funnel into the hose and pour four(4) ounces ofsanitary type (RV) antifreeze into the condensate trap. Re-connect the 5/8� OD rubber hose to the stub on the ventdrain fitting. Secure with the hose clamp.

2. Disconnect the 3/4�OD rubber hose from the condensatetrap. Insert a funnel into the hose and and pour four(4)ounces of sanitary type (RV) antifreeze into the plasticTransition box. Squeeze the hose together near the endand quickly reconnect the 3/4�OD rubber hose to the stubon the condensate trap. Secure with the hose clamp.

When you return home, your furnace will be ready to start, as it isnot necessary to drain the antifreeze from the furnace.

2. Installation

Poison carbon monoxide gas Hazard.

This furnace can NOT be common vented orconnected to any type B, BW or L vent or ventconnector, nor to any portion of a factory--built ormasonry chimney. If this furnace is replacing apreviously common-vented furnace, it may benecessary to resize the existing vent andchimney to prevent oversizing problems for theother remaining appliance(s). See Venting andCombustion Air Check in Gas Vent Installationsection. This furnace MUST be vented to theoutside.

Failure to properly vent this furnace or otherappliances can result in death, personal injuryand/or property damage.

!

Location and Clearances

1. Refer toFigure 1orFigure 2 for typical installationandba-sic connecting parts required. Refer to Figure 4 for typicalhorizontal direct vent installation and basic connectingparts required. Supply and return air plenums and duct arealso required.

2. If furnace is a replacement, it is usually best to install thefurnace where the old one was. Choose the location orevaluate the existing location based upon the minimumclearance and furnace dimensions (Figure 3).

CAUTION

Special precautions MUST be made if installingfurnace in an areawhichmaydropbelow freezing. Thiscan cause improper operation or damage toequipment. If furnace environment has the potential offreezing, the drain trap and drainline must beprotected. The use of electric heat tape or RVantifreeze is recommended for these installations.(See �Condensate Trap Freeze Protection Section�)

Do NOT operate furnace in a corrosive atmospherecontaining chlorine, fluorine or any other damagingchemicals. Refer to Combustion & Ventilation Airsection, Contaminated Combustion Air.

Vent Pipes MUST besupportedHorizontally andVertically

*8� Min.20� Max.in same atmospheric

zone

*8� Min.20� Max.in sameatmosphericzone

Coupling on ends ofexhaust pipe. Totalpipe & coupling out-side structure = 8�

Figure 1 Typical Upflow Installation

Aluminum or non--rusting shield recommended.(See Vent Termination Shielding for dimensions).

* Increase minimum from 8� to 18� for cold climates (sustained temperaturesbelow 0 � F).

DISCHA

RGEAIR

25--23--33

Inlet Pipe(not used onSingle Pipemodel)

*8� Min.20� Max.in sameatmosphericzone

Figure 2 Typical Downflow Installation

Vent Pipes MUST besupported Horizontallyand Vertically

* Increase minimum from 8� to 18� for cold climates (sustained temperaturesbelow 0�F).

See Vent TerminationShielding in Vent Section.

*8� Min.20� Max.in sameatmospheric zone

8� Min.

Coupling on insideand outside of wallto restrain vent pipe

25--23--33a

Inlet Pipe(not used onSingle Pipemodel)

Figure 3 Dimensions and Clearances

1913/16

TOP

F

G

H

E

21/4

24

11/4

3111/16

AIR INTAKE (Dual Certified orDirect Vent)

11/16

297/8

VENT (Dual Certified)

283/4

ELECTRICAL

LEFT SIDE

7

AIR INTAKE(ALTERNATE)

413/16

241/16

13/8

175/16

111/16

VENT

BOTTOM

TRAP (DOWNFLOW)

GAS

17/8

D

131/4

TRAPUPFLOW/HORIZONTAL

215/8 47/8

37/8231/8

THERMOSTAT

AB

FRONT

111/16

3311/16

11/16

297/8

413/16

7

AIR INTAKE(ALTERNATE)

23/8

45/16

VENT

TRAP (DOWNFLOW)

GAS

THERMOSTAT

40113/16

ELECTRICAL

24

281/2

181/21/2TYP.

273/16

47/8

11/16

RIGHT SIDE

215/8

175/16

21/4

17/8

131/4

215/8

25--23--36A

611/16

1311/16

1913/16

ALL DIMENSIONS IN INCHES

TRAP(UPFLOW/HORIZONTAL)

6 440 01 2010 04

Cabinet to Combustible ClearancesTOP BOT. RH LH BACK FRONT FLUE

1� 0� 0� 0� 0� 3� 0�

Unit Cabinet Bottom TopUnit Cabinet Bottom TopUnit

Capacity A B D E F G H

*9MPT050F12A 191/8 175/8 143/4 43/8 41/2 21/2 91/2*9MPT075F12A 191/8 175/8 143/4 43/8 41/2 21/2 91/2*9MPT100J16A 223/4 211/4 183/4 43/8 41/2 25/8 113/8*9MPT125L20A 241/2 23 23 43/8 41/2 21/4 121/4*9MPV050F12A 191/8 175/8 143/4 43/8 41/2 21/2 91/2*9MPV075F12A 191/8 175/8 143/4 43/8 41/2 21/2 91/2*9MPV100J20A 223/4 211/4 183/4 43/8 41/2 25/8 113/8*9MPV125L20A 241/2 23 23 43/8 41/2 21/4 121/4

7440 01 2010 04

Installation Requirements1. Install furnace level.2. This furnace isNOT to be used for temporary heat of build-

ings or structures under construction.

3. Install furnaceascentralizedaspracticalwith respect to theheat distribution system.

4. Install the vent pipes as short as practical. (See Vent andCombustion Air Piping section).

5. Maintain clearance for fire safety and servicing. A frontclearance of 30� is recommended for access to the burner,controls and filter.

6. Use a raised base for upflow furnace if the floor is damp orwet at times.

7. For downflow installations, non combustible subbasemustbe used under the furnace unless installation is on a noncombustible floor surface. This requirement applies evenwhen a coil box or cabinet is used.

Fire Hazard.

Place furnace on noncombustible subbase ondownflow applications, unless installing onnon--combustible flooring.

Failure to install unit on noncombustiblesubbase can result in death, personal injuryand/or property damage.

!

8. For horizontal installations, line contact is permissible onlybetween lines formed by intersection of back and two sidesof furnace jacket, and building joists, studs or framing.

9. Residential garage installations require:

� Burners and ignition sources installed at least 18�abovethe floor.

� Located or physically protected from possible damageby a vehicle.

10. Local codes may require a drain pan under the entire fur-nace and condensate trap when the furnace is installed inattic application.

Installation PositionsThis furnace canbe installed in an upflow, horizontal (either left orright) or downflow airflow position. DONOT install this furnace onits back. For the upflow position, the return air ductwork can beattached toeither the left or right sidepanel and/or thebottom.Forhorizontal and downflow positions, the return air ductwork mustbe attached to the bottom. The return air ductworkmust never beattached to the back of the furnace.

Furnace Installation ConsiderationsThe installation of the furnace for a given application will dictatethe position of the furnace, the airflow, ductwork connections,vent and combustion air piping. Consideration must be given tothe following:

Condensate Trap and Drain LinesThe supplied condensate trap must be attached to the furnaceside panel on either the left or right side. For horizontal installa-tions, the drain trap is vertically attached to the side panel belowthe furnace. A minimum clearance of 5� below the furnace is re-

quired for the condensate trap. Downward slope of the conden-sate drain line from the condensate trap to the drain locationmustbe provided. Adequate freeze protection of the drain trap and thedrain linemust beprovided.See �CondensateDrainTrap�sectionfor further details.

LevelingProper leveling of the furnace must be provided to insure properdrainage of the condensate from the furnace. The furnace mustbe level to within 1/4� from front to back and from side to side forupflow and downflow installations or top to bottom for horizontalinstallations.

Vent and Combustion Air ConnectionsOn the Dual Certified furnace, the vent and combustion air pipesattach to the furnace through the top panel for theupflowandhori-zontal installations. For the downflow installation, the vent andcombustion air pipes attach to the furnace through the alternatelocations on the furnace side panels.

Note:On theDirectVent furnace, the vent pipe attaches to the fur-nace through thesidepanels.Thecombustionairpipeattaches tothe top panel or to the alternate location on the side panel.On the Single Pipe furnace, the vent pipe attaches to the furnacethrough the furnace side panels.

Note: Repositioning of the combustion blower is required for thevent pipe connection to the furnace through the �right side� panel.See �Vent and Combustion Air Piping� section for further details.

Horizontal Furnace InstallationThis furnace can be installed horizontally in an attic, basement,crawl space, alcove, or suspended fromaceiling inabasementorutility room . See Figure 4. Do not install furnace on its back or inthe reverseairflowpositionsas safetycontrol operationwill bead-versely affected.

Inlet Pipe (not used on Single Pipe model)

Typical Horizontal InstallationFigure 4

VentPipe

CondensateTrap

NOTE: 5� bottom clearance required for condensate trap.25--23--34

If the furnace is to be suspended from the floor joists in a crawlspace or the rafters in an attic, it is necessary to use steel pipestraps or an angle iron frame to ridgely attach the furnace to pre-vent movement. These straps should be attached to the furnacewith sheet metal screws and to the rafters or joists with bolts. Thepreferredmethod is touseanangle iron framebolted to the raftersor joists. (Take caution to allow door panels to be removed formaintenance)

8 440 01 2010 04

If the furnace is to be installed in a crawl space, consult localcodes. A suitable concrete pad or blocks are recommended forcrawl space installation on the ground.

NOTE: 5� bottom clearance required for condensate trap.

Thirty (30) inches between the front of the furnace and adjacentconstruction or other appliancesMUST bemaintained for serviceclearance.

Keep all insulating materials clear from louvered door. Insulatingmaterials may be combustible.

The horizontal furnaces may be installed directly on combustiblewood flooring or supports as long as all required furnace clear-ances are met. See Figure 3.

This furnace MUST NOT be installed directly on carpeting or tileor other combustible material other than wood flooring or sup-ports.

For horizontal installation over a finished living space. A field fab-ricated auxiliary drain panwith drain pipe is recommended to pre-vent damage by overflow due to blocked condensate drain.

3. Combustion & Ventilation Air


Use methods described here to providecombustion and ventilation air.

Failure to provide adequate combustion andventilation air can result in death and/orpersonal injury.

!

Venting and Combustion Air Check

NOTE: The following information is supplied to allow the installerto make adjustments to the setup of existing appliances, IFREQUIRED, based on good trade practices, local codes, andgood judgement of the installer. Manufacturer doesNOT take re-sponsibility for modifications made to existing equipment.

NOTE: If this installation replaces an existing furnace from acommonly vented system,make sure there is adequate combus-tion air for all appliances, MAKE THE FOLLOWING CHECK.

1. Seal any unused openings in the venting system.

2. Visually inspect the venting system for proper size andhor-izontal pitch to ensure there is no blockage or restriction,leakage, corrosion or other deficiencieswhich could causean unsafe condition.

3. Insofar as is practical, close all doors and windows and alldoors between thespace inwhich theappliance(s) remain-ing connected to the venting system are located and otherspaces of the building.

4. Turn on clothes dryers and any appliance not connected tothe venting system. Turn on any exhaust fans, such asrange hoods and bathroom exhausts, so they will operateatmaximumspeed. Do not operate a summer exhaust fan.Close fireplace dampers.

5. Follow the lighting instructions for each appliance being in-spected. Adjust thermostat so appliance(s) will operatecontinuously.

6. Allow 5 minutes of main burner operation, then check forspillage at the draft hood relief opening of each appliance.Use the flame of a match or candle (Figure 5).

Vent Check

Draft HoodVent Pipe

MatchTypical GasWater Heater

Figure 5

7. After it has been determined that each appliance ventsproperly, return doors, windows, appliances etc. to theirnormal condition.

8. If improper venting is observed, the cause MUST be cor-rected using the appropriate tables in code books of coun-try having jurisdiction.

NOTE: If flame pulls towards draft hood, this indicates sufficientventing.

NOTE: Non direct vent appliances occupying same enclosedspace as furnaceMUST have enough air for proper combustionandventilation.All ductoropenings forsupplying combustionandventilationairmust complywith thegasandelectrical codesof thecountry having jurisdiction.

When the installation is complete, check that all appliances haveadequate combustion air and are venting properly. See VentingAnd Combustion Air Check in this manual.

Air Openings and Connecting Ducts1. Total input rating for all non direct vent gas appliances

MUST be considered when determining free area of open-ings.

2. Connect ducts or openings directly to outside.

3. When screens are used to cover openings, theyMUST beno less than 1/4� mesh.

4. The minimum dimension of rectangular air ducts MUSTNOT be less than 3�.

5. When sizing grille or louver, use the free area of opening. Iffree area is NOT stamped or marked on grill or louver, as-sume a 20% free area for wood and 60% for metal.

Confined Space InstallationNOTE: A confined space is defined as an area with less than 50cubic feet per 1,000 BTUH input rating for all gas appliancesinstalled in the area.

Requirements1. Provide confined space with sufficient air for proper com-

bustion and ventilation of flue gases using horizontal orvertical ducts or openings.

9440 01 2010 04

2. Figure 6 illustrate how to provide combustion and ventila-tion air. A minimum of two permanent openings, one inletand one outlet, are required.

3. One opening MUST be within 12� of the floor and the se-cond opening within 12� of the ceiling.

4. Size openings and ducts per Table 1.

5. Horizontal duct openings require 1� square of free area per2,000 BTUH of combined input for all gas appliances inarea (see Table 1).

6. Vertical duct openings or openings directly to outside re-quire 1� square of free area per 4,000 BTUH for combinedinput of all gas appliances in area (see Table 1).

Minimum One Inlet and One Outlet Air Supply is RequiredMay be in and Combination Shown

Inlet Air Opening Must be Within12� of floor

Outlet Air Opening Must be Within12� of ceiling

(1) 1 Square Inch per 4000 BTUH

(2) 1 Square Inch per 2000 BTUH

Outside Air (This is ONLY a guide. Subject to codes of country having jurisdiction.)Figure 6

This installation NOT approved in Canada

Gas Vent

Gable Vent

Ventilated AtticTop Above Insulation

Optional Inlet Air (1)

Ventilated Crawl Space

Outlet Air (1) Soffit Vent OutletAir (1)

InletAir (1)

OutletAir (2)

InletAir (2)

Gas Vent

InletAir (2)

Soffit Vent

Gas VentGable Vent

Ventilated AtticTop Above Insulation

InletAir (1)

OutletAir (1)

Table 1 Free Area

Minimum Free Area Required for Each OpeningBTUHInputRating

Horizontal Duct(2,000 BTUH)

Vertical Duct or openingsto outside(4,000 BTUH)

RoundDuct(4,000BTUH)

50,000 25 sq. in. 12.5 sq. in. 4�75,000 37.5 sq. in. 18.75 sq. in. 5�100,000 50 sq. in. 25 sq. in. 6�

125,000 62.5 sq. in. 31.25 sq. in. 7�

150,000 75 sq. in. 37.5 sq. in. 7�

EXAMPLE: Determining Free AreaAppliance 1 Appliance 2 Total Input

100,000 + 30,000 = (130,000 � 4,000) = 32.5 Sq. In. Vertical

Appliance 1 Appliance 2 Total Input

100,000 + 30,000 = (130,000 � 2,000) = 65 Sq. In. Horizontal

One permanent opening, commencingwithin 12� of the top of theenclosure, shall be permitted where the equipment has clear-ances of at least 1� from the sides and back and 6� from the frontof the appliance. Theopeningshall directly communicatewith theoutdoors or shall communicate through a vertical or horizontalduct to theoutdoorsorspaces (crawlor attic) that freely communi-cate with the outdoors, and shall have a minimum free area of:

� 1 sq. in per 3000 Btu per hr. of the total input rating of allequipment located in the enclosure, and

� Not less than the sumof the areas of all vent connectorsin the confined space.

Unconfined Space Installation


Most homes will require additional air.

An unconfined space or homes with tightconstruction may not have adequate airinfiltration for proper combustion and ventilationof flue gases.

Failure to supply additional air by means ofventilation grilles or ducts could result in deathand/or personal injury.

!

Anunconfined space is definedas anarea havingaminimumvol-ume of 50 cubic feet per 1,000 Btuh total input rating for all gasappliances in area. Refer to Table 2 for minimum area required.

Table 2 Unconfined SpaceMinimum Area in Square Feet

BTUH InputRating Minimum Area in Square Feet

50,000 312

78,000 490

114,000 712

155,000 968

EXAMPLE: NOTE: Square feet is based on 8 foot ceilings.

28,000 BTUH X 50 Cubic Ft. = 1,400 = 175 Sq. Ft.1,000 8� Ceiling Height

10 440 01 2010 04

NOTE: Refer to definitions in section titled Unusually TightConstruction. If any one of the conditions apply, the spaceMUSTbe considered confined space regardless of size.

1. Adjoining rooms can be considered part of an unconfinedarea if there are openings without doors between rooms.

2. An attic or crawl space may be considered an unconfinedspaceprovided thereareadequateventilationopeningsdi-rectly to outdoors. OpeningsMUST remain open andNOThaveanymeansofbeingclosedoff.Ventilationopenings tooutdoorsMUSTbeat least 1� square of free area per4,000BTUH of total input rating for all gas appliances in area.

3. Install air intake a minimum of 12� above maximum snowlevel and clear of any obstruction. Duct or ventilation open-ing requires one square inch of free area per 4,000 BTUHof total input rating for all gas appliances in area.

4. Air inlet MUST be screened with not less than 1/4� meshscreen.

Unusually Tight ConstructionIn unconfined spaces, infiltration may be adequate to provide airfor combustion, ventilation and dilution of flue gases. However, in

buildings with unusually tight construction, additional air MUSTbe provided using the methods described in section titled Con-fined Space Installation:

Unusually tight construction is defined as: Construction with

1. Walls and ceilings exposed to the outside have a continu-ous, sealed vapor barrier. Openings are gasketed orsealed and

2. Doors and openable windows are weather stripped and

3. Otheropeningsare caulkedor sealed.These include jointsaround window and door frames, between sole plates andfloors, betweenwall--ceiling joints, betweenwall panels, atpenetrations for plumbing, electrical and gas lines, etc.

Ventilation Air

Someprovincial codesand localmunicipalities requireventilationormake--up air be brought into the conditioned space as replace-ment air. Whichevermethod is used, themixed return air temper-ature across the heat exchangerMUST not fall below60�F or fluegases will condense in the heat exchanger. This will shorten thelife of the heat exchanger and possibly void your warranty.

4. Vent and Combustion Air Piping

Poison carbon monoxide gas, fire and explo-sion hazard.

Read and follow all instructions in this section.

Failure to properly vent this furnace can result indeath, personal injury and/or property damage.

!

Dual Certified (*9MPT & *9MPV Models)This furnace is certified as a category IV appliance. This furnacecan be installed as a direct vent furnace using outside air for com-bustion or the furnace can use air from inside the structure forcombustion. The INLET air pipe is optional. If combustion aircomes from inside the structure, adequatemake up airMUST beprovided to compensate for oxygen burned. See ConfinedSpace Installation in the Combustion and Ventilation Airchapter. If combustion air is drawn from outside the structure, itMUST be taken from the sameatmospheric pressure zone as thevent pipe.

Contaminated Combustion AirInstallations in certain areas or types of structures will increasethe exposure to chemicals or halogens that may harm the fur-nace.

The followingareasor typesof structuresmaycontainor haveex-posure to the substances listed below. The installation must beevaluated carefully as it may be necessary to provide outside airfor combustion.

� Commercial buildings.

� Buildings with indoor pools.

� Furnaces installed in laundry rooms.

� Furnaces installed in hobby or craft rooms.

� Furnaces installed near chemical storage areas.

� Permanent wave solutions for hair.

� Chlorinated waxes and cleaners.

� Chlorine based swimming pool chemicals.

� Water softening chemicals.

� De--icing salts or chemicals.

� Carbon tetrachloride.

� Halogen type refrigerants.

� Cleaning solvents (such as perchloroethylene).

� Printing inks, paint removers, varnishes, etc.

� Hydrochloric acid.

� Sulfuric Acid.

� Solvent cements and glues.� Antistatic fabric softeners for clothes dryers.

� Masonry acid washing materials.

Vent and Combustion Air Piping GuidelinesNOTE:All vent pipingMUST be installed in compliance with localcodes or ordinances, these instructions, good trade practices,and codes of country having jurisdiction.

1. Determine the best routing and termination for the ventpipe and air inlet pipe by referring to all of the instructionsand guidelines in this Section.

2. Determine the size required for the vent pipe and air inletpipe.

3. Loosely assemble all venting parts without adhesive (pipejoint cement) for correct fit before final assembly.

4. Use of vertical piping is preferred because there will besome moisture in the flue gases that may condense as itleaves the vent pipe (See Special Instruction For Horizon-tal Vents).

5. The vertical vent pipe MUST be supported so that noweight is allowed to rest on the combustion blower.

6. Exhaust vent piping or air inlet piping diameterMUSTNOTbe reduced.

11440 01 2010 04

7. All exhaust vent piping from the furnace to terminationMUST slope upwards. A minimum of 1/4� per foot of run isrequired to properly return condensate to the furnace drainsystem.

8. Use DWV type long radius elbows whenever possible, asthey provide for the minimum slope on horizontal runs andthey provide less resistance in the vent system. If DWV el-bows cannot be used, use two, 45� elbows when possible.On horizontal runs the elbows can be slightlymisaligned toprovide the correct slope.

9. All horizontal pipe runsMUST be supported at least everyfive feetwith galvanizedstraporother rust resistantmateri-al. NO sags or dips are permitted.

10. All vertical pipe runs MUST be supported every six feetwhere accessible.

11. The maximum pipe length is 40� total in the inlet or outletside of the system. Up to five, 90� elbows can be used onthe inletor the outlet.With theConcentric VentTerminationKits (NAHA001CV or NAHA002CV), the maximum pipelength is 35�with 490�elbows. Ifmoreelbowsare required,reduce the length of both the inlet and exhaust pipes 5� foreach additional elbow used. (See Table 3 or Table 4).

12. The minimum pipe run length is 2�.

13. Thepipingcanbe run in thesamechaseoradjacent tosup-ply or vent pipe for water supply or waste plumbing. It canalso be run in the same chasewith a vent fromanother 90+furnace.

NOTE: In NO case can the piping be run in a chase wheretemperatures can exceed 140� F. or where radiated heatfrom adjacent surfaces would exceed 140� F.

14. The vent outletMUST be installed to terminate in the sameatmospheric pressure zone as the combustion air inlet.

15. The vent system can be installed in an existing unusedchimney provided that:

� Both the exhaust vent and air intake run the length of thechimney.

� No other gas fired appliance or fireplace (solid fuel) isvented into the chimney.

� The top of the chimney MUST be sealed flush orcrownedup to seal against rain ormelting snowsoONLYthe piping protrudes.

� The termination clearances shown inFigure 7aremain-tained.

16. Furnace applications with vertical vents requiring vent di-ameter increaser fittings must have increaser fittingsinstalled in vertical portion of the vent. Condensate will betrapped in the vent if the vent diameter is increased prior tohaving an elbow turned upward. This could cause nui-sance tripping of the pressure switch.

Piping Insulation Guidelines

NOTE: Use closed cell, neoprene insulation or equivalent. If Fi-berglass or equivalent insulation is used itmust have a vapor bar-rier. Use R values of 7 up to 10�, R--11 if exposure exceeds 10�. IfFiberglass insulation is used, exterior to the structure, the pipeMUST be boxed in and sealed against moisture.

1. .When the vent or combustion air pipe height above theroof exceeds 30�, or if an exterior vertical riser is used on ahorizontal vent to get above snow levels, the exterior por-tion MUST be insulated.

2. When combustion air inlet piping is installed above a sus-pended ceiling, the pipeMUST be insulated with moistureresistant insulation such as Armaflex or other equivalenttype of insulation.

3. Insulate combustion air inlet piping when run in warm, hu-mid spaces such as basements.

Sizing Combustion Air and Vent PipeConsult Table 3 or Table 4 to select the proper diameter exhaustand combustion air piping. Exhaust and combustion air piping issized for each furnace Btuh size based on total lineal vent length(on inlet or outlet side), and number of 90� elbows required.

1. Double Pipe Installation--If installing as a direct--vent ap-pliance, consult Table 4 to select the proper diameter ex-haust and combustion air piping. Exhaust and combustionair piping is sized for each furnaceBtuh size based on totallineal vent length (on inletoroutlet side), andnumberof90�elbows required.

2. Single Pipe Installation--If installing as a non--direct ventappliance, (single outlet pipe and no inlet pipe) refer toTable 3. The table shows the maximum number of elbowsallowed with any given pipe diameter and length of run.

3. UseofElbows--Two45�elbowscanbesubstituted for one90� elbow. The elbow or elbows used for vent terminationoutside thestructureAREcounted, includingelbowsneed-ed to bring termination above expected snow levels.

Table 3 Pipe Diameter TableSingle Piping ONLY

50,000 & 75,000 Btuh Furnaces40�� & (5) 90� elbows with 2� PVC pipe or

100,000 Btuh Furnace40�� & (5) 90� elbows with 3� PVC pipe

125,000 Btuh Furnace40�� & (5) 90� elbows with 3� PVC pipe

Elbows are DWV Long Radius Type for 2� and 3� vents.

If more than five elbows are required, reduce the length ofboth the inlet and exhaust pipes 5� for each additional elbowused.

NOTE: It is allowable to use larger diameter pipe and fitting thanshown in the tables but not smaller diameters than shown.

Table 4 Pipe Diameter TableDual Piping ONLY

50,000 & 75,000 Btuh Furnaces40�� & (5) 90� elbows with 2� PVC pipe or

100,000 Btuh Furnace40� & (5) 90� elbows with 3� PVC pipe

125,000 Btuh Furnace40� & (5) 90� elbows with 3� PVC pipe

Elbows are DWV Long Radius Type for 2� and 3� vents.

If more than five elbows are required, reduce the length ofboth the inlet andexhaust pipes 5� for each additional elbowused.

*Feet of pipe iswhichever pipe run is the longest, either inletor outlet side.

12 440 01 2010 04

For �Concentric Termination Kit� Venting table, see�Section 10� in this manual.

Vent Termination Clearances


Inlet and outlet pipes may NOT be venteddirectly above each other.


!

1. Determine termination locations basedon clearances spe-cified in following steps and as shown in Figure 7,Figure 13, through Figure 20.

For �Concentric Termination Kit� clearances, see Figure 40,Figure 41, Figure 42, Figure 43andFigure 44 in �Section10�in this manual.

2. The vent termination must be located at least 12� aboveground or normally expected snow accumulation levels.

3. Do NOT terminate over public walkways. Avoid areaswhere condensate may cause problems such as aboveplanters, patios, or adjacent to windows where steammaycause fogging.

4. Thevent terminationshall be locatedat least 4�horizontallyfromany electricmeter, gasmeter, regulator, and any reliefequipment. These distances apply ONLY to U.S. installa-tions.

5. The vent termination is to be located at least 3� above anyforced air inlet located within 10� ; and at least 10� from acombustionair intakeof anotherappliance, exceptanotherdirect vent furnace intake.

6. In Canada, the Canadian Fuel Gas Code takes prece-dence over the preceding termination instructions.

Vent Termination Clearances(United States Only)

Figure 7

In Canada See Canadian Fuel Gas Code

Direct VentTerminal

50,000 Btuhor less

Other ThanDirect VentTerminal

Direct Vent TerminalMore Than 50,000 Btuh



Forced AirInlet

10--11--36

9�

12�

12�

12�

12�

12�

10�

3�

4�

4�

Condensate Drain TrapThis furnace removesbothsensibleand latent heat from theprod-ucts of combustion. Removal of the latent heat results in con-densation of the water vapor. The condensate is removed fromthe furnace through thedrains in theplastic transitionand theventfitting. The drains connect to the externally mounted condensatedrain trap on the left or right side of the furnace.

The condensate drain trap supplied with the furnace MUST beused. The drain line between the condensate drain trap and thedrain locationmay be constructed of 3/4�PVC, CPVCpipe or oth-er suitable material.

The drain line must maintain a 1/4� per foot downward slope to-ward the drain.

DO NOT trap the drain line in any other location than at the con-densate drain trap supplied with the furnace.

Frozen water pipe hazard.

When activated an auxiliary safety switch willcause a furnace not to operate.

During freezing temperatures the water pipes inyour home could freeze and burst causing waterdamage to the home.

Do not leave the home unattended during freezingtemperatures, or shut off the water supply anddrain the pipes before leaving.

!

If possible DO NOT route the drain line where it may freeze. Thedrain line must terminate at an inside drain to prevent freezing ofthe condensate and possible property damage.

1. A condensate sump pumpMUST be used if required by lo-cal codes, or if no indoor floor drain is available. The con-densate pump must be approved for use with acidiccondensate.

2. A plugged condensate drain line or a failed condensatepump will allow condensate to spill. If the furnace isinstalled where a condensate spill could cause damage, itis recommended that anauxiliary safety switch be installedto prevent operation of the equipment in the event of pumpfailure or plugged drain line. If used, an auxiliary safetyswitch should be installed in the R circuit (low voltage)ONLY.

Condensate Drain Trap Freeze ProtectionSpecial precautions MUST be made if installing furnace in anareawhichmaydropbelow freezing.This cancause improperop-eration or damage to the equipment. If the the furnace environ-ment has the potential of freezing, the drain trap and drain linemust be protected. Use 3 to 6 watt per foot at 115 volt, 40� F self--regulating shielded andwaterproof heat tape.Wrap the drain trapand drain line with the heat tape and secure with the ties. Followthe heat tape manufacturer�s recommendations.

13440 01 2010 04

Figure 8 Upflow Installations (Dual Certified *9MPT & *9MPV Models)

Supply Air

Exhaust

Inlet

Return Air

Vent Pipe

Vent Pipe Grommet

Vent Fitting & Clamps

Rubber Plug

Drain Line

90�� Elbow

Plastic Caps

Rubber Coupling& Clamps5/8�� Hose & Clamps

CombustionAir Pipe (optional)

Air Intake Coupling

Combustion Blower

Pressure Switch Hose,Transition

Pressure Switch,Transition(Lo Fire)

3/4�� Hose& Clamps

CondensateTrap & Gasket(Left or Right Side)

Plastic Caps

Gas Pipe Grommet

Transition Box

CombustionBlowerMountingScrews (4)

Pressure SwitchHose, Blower

Pressure Switch,Blower (Hi Fire)

AIR FLOW

25--23--53a

RIGHT Side VentingLEFT Side Venting

clampRubberHose

RubberHose

clamp

RigidPlasticDrainTube

25--23--53b

Inlet

Exhaust

Rigid PlasticDrain Tube

Rotatedownward20� to 30�

DRAIN SIDE VIEW

Upflow Installations - (Dual Certified *9MPT & *9MPV) (See Figure 8)Mount the condensate drain trap in a vertical position to either theleft or right side of the furnace using the two screws and gasketthat are provided. If needed, remove the hole plugs from the fur-nace side panel and relocate to the open set of holes in the oppo-site side panel. Drill two 7/64� diameter holes in the casing usingthe condensate trap as the template.

Ensure that the vent fitting and the 90�elbow is securely attachedto the combustion blower.

This configurationallows left side venting from the furnace. If rightsideventing is required, thecombustionblowermust be relocatedon the plastic transition box. Remove the four(4) screws that se-cure the blower to the transition. Rotate the blower 180� and se-cure with the four(4) screws. Use caution to not over tighten thescrews to prevent stripping out of the plastic mounting holes.

For right side venting, removevent fittingassembly fromcombus-tion blower. Remove 90� elbow and rubber tubing from the ventfitting by loosening the clamp on the vent fitting. Securely attachvent fitting directly to combustion blower.

NOTE:Thevent fittingMUSTbe installedwith the airflowmarkingarrow pointed toward the vent pipe, with the drain stub at a 20� to30� downward slope.

Plug the right drain stubof thevent fittingwith the rubberplug.Usea blunt pointed screwdriver to push the plug into the stub.

For left side mounted condensate trap, connect the 3/4�OD rub-ber hose with the 90� bend to the drain stub on the bottom of theplastic transition box and secure with a 3/4� clamp.

Route thehose to the largedrain stubon thecondensate trap.Cutoff excess hose and discard. Connect the hose to the drain stubon the trap and secure with a 3/4� clamp.

For right sidemounted condensate trap, the rigid plastic draintube MUST be used. Cut two 2� long sections from the 3/4� ODrubber hose. Connect the plastic drain tube to the drain stub onthe bottom of the plastic transition box and to the stub on the con-densate trap using the two hose sections and 3/4� clamps.NOTE: The support leg on the plastic drain tube MUST be posi-tioned on the blower partition.

Connect the 5/8�ODrubberhosewith the 90�bend to the left drainstub on the vent fitting and secure with a 5/8� clamp.

Route thehose to thesmall drain stubon thecondensate trap.Cutoff excess hose and discard. Connect the hose to the drain stubon the trap and secure with a 5/8� clamp.

NOTE:Ensure hoses maintain a downward slope to the conden-sate trap with no kinking or binding for proper condensate drain-age.

14 440 01 2010 04

Combustion BlowerMounting Screws(4)

Figure 9 Horizontal Left Installations (Dual Certified *9MPT & *9MPV)

SupplyAir

Exhaust

Inlet

Vent Pipe

Vent PipeGrommet

Vent Fitting& Clamps

RubberPlug

Drain Line

90�� Elbow

Plastic Caps

Rubber Coupling& Clamps

5/8�� Hose & Clamps

Combustion Air Pipe, (optional)

Air Intake Coupling

CombustionBlower

Pressure Switch Hose,Transition

Pressure Switch,Transition (Lo Fire)


CondensateTrap & Gasket

dwg 25--23--54a

ReturnAir

Plastic Caps

Transition Box

Gas PipeGrommet

Pressure Switch Hose,Blower


DRAIN SIDE VIEW

Rotate downward20� to 30�

Horizontal Left Installations - (Dual Certified *9MPT & *9MPV) (See Figure 9)Relocate the plastic caps and clamps on the condensate draintrap from the vertical drain stub to the horizontal drain stubs. Se-cure the clamps tightly to prevent condensate leakage.

Mount the condensate drain trap in a vertical position to the leftside of the furnace using the two screws and gasket that are pro-vided. Note: The condensate trap will be located under the fur-nace in a vertical position when the furnace is placed horizontallyon the left side. If needed, remove the hole plugs from the furnaceside panel and relocate to the open set of holes in the oppositeside panel. Drill two 7/64� diameter holes in the casing using thecondensate trap as the template.



Plug the upper drain stub on the vent fitting with the rubber plug.Use a blunt pointed screwdriver to push the plug into the stub.

Connect the 3/4� OD rubber hose with the 90� bend to the drainstub on the bottom of the plastic transition box and secure with a3/4� clamp.


Connect the 5/8� OD rubber hose with the 90� bend to the smalldrain stub on the trap and secure with a 5/8� clamp.

Route the hose to the lower drain stub on the vent fitting. Cut offexcess hose and discard. Connect the hose to the drain stub onthe vent fitting and secure with a 5/8� clamp.


15440 01 2010 04

Figure 10 Horizontal Right Installations (Dual Certified *9MPT & *9MPV)

SupplyAir

Exhaust

Inlet

Vent Pipe

Vent PipeGrommet


Rubber Plug

Drain Line

90�� Elbow

Plastic Caps

Rubber Coupling & Clamps


CombustionAir Pipe(Optional)

Air IntakeCoupling

CombustionBlower

Pressure SwitchHose, Transition

Pressure Switch, Transition(Lo Fire)

3/4�� Hose & ClampsCondensate Trap& Gasket

dwg 25--23--55a

ReturnAir

Plastic Caps

Transition Box

Gas PipeGrommet

Combustion BlowerMountingScrews (4)


Pressure SwitchHose, Blower DRAIN SIDE VIEW


Horizontal Right Installations - (Dual Certified *9MPT & *9MPV) (See Figure 10)Relocate the plastic caps and clamps on the condensate draintrap from the vertical drain stub to the horizontal drain stubs. Se-cure the clamps tightly to prevent condensate leakage.

Mount the condensate drain trap in a vertical position to the rightside of the furnace using the two screws and gasket that are pro-vided. Note: The condensate trap will be located under the fur-nace in a vertical position when the furnace is placed horizontallyon the right side. If needed, remove the hole plugs from the fur-nacesidepaneland relocated to theopensetof holes in theoppo-site side panel. Drill two 7/64� diameter holes in the casing usingthe condensate trap as the template.


NOTE:Thevent fittingMUSTbe installedwith the airflowmarkingarrow pointed toward the vent pipe, with the drain stub at a 20�downward slope.


Remove the pressure switch hose from the upper stub on theplastic transition box.

Relocate the plastic caps on the stubs of the plastic transition boxfrom the lower stubs to the upper stubs and secure tightly with theclamps.

Route the pressure switch hose to the lower stub on the plastictransitionbox.Cutoff excesshoseanddiscard.Connect thepres-sure switch hose to the lower stub on the plastic transition box.NOTE: Failure to correctly install the pressure switch hose to thetransition can adversely affect the safety control operation.



Connect the 5/8� OD rubber hose with the 90� bend to the lowerdrain stub on the vent fitting and secure with a 5/8� clamp.

Route the hose to the smaller drain stub on the condensate trap.Cut off excess hose and discard. Connect the hose to the drainstub on the trap and secure with a 5/8� clamp.


16 440 01 2010 04

Pressure SwitchHose, Transition

Pressure Switch,Blower(Hi Fire)

Pressure SwitchHose, Blower


PlasticCaps

Figure 11 Downflow Installations (Dual Certified *9MPT & *9MPV Models)

Vent Pipe

Vent PipeGrommet


CombustionAir Pipe, (Optional)

dwg 25--23--56a

Supply Air

Exhaust

Inlet

Air IntakeCoupling

Combustion Blower(Rotate 180�� for Left Side)

RIGHT Side Venting

Drain Line

PlasticCaps

Pressure Switch,Transition(Lo Fire)

RubberPlug

5/8�� Hose &Clamps

CondensateTrap & Gasket

3/4�� Hose& Clamps

Return Air

LEFT Side Venting

Exhaust

Supply Air

Inlet

Combustion BlowerMounting Screws (4)

TransitionBox

Gas PipeGrommet

Return Air

DRAIN SIDE VIEW

Downflow Installations - (Dual Certified *9MPT & *9MPV Models) (See Figure 11)Mount the condensate drain trap in a vertical position to either theright or left side of the furnace using the two screws and gasketthat are provided. If needed, remove the hole plugs from the fur-nacesidepaneland relocated to theopensetof holes in theoppo-site side panel. Drill two 7/64� diameter holes in the casing usingthe condensate trap as the template.

Ensure that the vent fitting is securely attached to the combustionblower using the clamp.


For right side venting, removevent fittingassembly fromcombus-tion blower. Remove 90� elbow and rubber tubing from the ventfitting by loosening the clamp on the vent fitting. Securely attachvent fitting directly to combustion blower.

This configurationallows right side venting from the furnace. If theleft side venting is required, the combustion blower must be relo-cated on the plastic transition box. Remove the three(4) screwsthat secure the blower to the transition. Rotate the blower 180�and securewith the three(3) screws.Usecaution tonot over tight-en the screws to prevent stripping out of the plastic mountingholes.


Remove the pressure switch hose from the upper stub on theplastic transition box.

Relocate the plastic caps on the stubs of the plastic transition boxfrom the lower stubs to the upper stubs and secure tightly with theclamps.

Route the pressure switch hose to the lower stub on the plastictransitionbox.Cutoff excesshoseanddiscard.Connect thepres-sure switch hose to the lower stub on the plastic transition box.NOTE: Failure to correctly install the pressure switch hose to thetransition box can adversely affect the safety control operation.



Connect the 5/8� OD rubber hose with the 90� bend to the lowerstub on the vent fitting and secure with a 5/8� clamp.

Route the hose to the smaller stub on the condensate trap. Cut offexcess hose and discard. Connect the hose to the drain stub onthe trap and secure with a 5/8� clamp.


17440 01 2010 04

Connecting Vent and Combustion Air Piping

Poison carbon monoxide gas hazard.

Cement or mechanically seal all joints, fittings,etc. to prevent leakage of flue gases.

Failure to properly seal vent piping can result indeath, personal injury and/or property damage.

!

Refer to the Figure 8 through Figure 11 that corresponds to theinstallation position of the furnace for the application.

Preassemble the vent and combustion air piping from the furnaceto thevent termination.Donot cement thepipe joints until thepipepreassembly process is complete.

Combustion Air Pipe Connection (Dual Certified orDirect Vent)

Install the air intake coupling and gasket to the furnace with thefour(4) screws. (See Figure 8 through Figure 11)Note: For the upflow and horizontal installations, the air intakecoupling and gasket must be installed to the top panel of the fur-nace.

Fordownflow installation, theair intakecouplingandgasketmustbe installed to the alternate air intake location on either the left orright side panels. Remove the 3� hole plug from the side paneland relocate to the air intake hole in the top panel. Use the fourscrews to seal the four(4) mounting holes in the top panel next tothe hole plug. Drill four(4) 7/64�diameter holes in the casing usingthe air intake coupling as the template.

The air intake coupling is sized for 2� PVC pipe.

Install the combustionair pipe to theair intakecouplingusingRTVsealant to provide for future serviceability.

Vent Pipe Connection

Install the vent pipe grommet to the furnace panel. Locate thegrommet in the furnace panel at a location directly away from thevent fittingon thecombustionblower.Thegrommetsnaps into the3� hole plug from the furnace panel. NOTE: Depending on theinstallation position, the vent pipe grommet will be installed to thetoppanel or to thealternate locationon thesidepanels. If needed,remove the3�holeplug from the furnacepanel and relocate to theopen hole in the furnace panel. See Figure 8 through Figure 11.

The vent pipe grommet is sized for 2� PVC pipe.

Install the vent pipe to the vent fitting on the combustion blowerusing the clamp.

Note: The vent fitting MUST be installed with the air flowmarking arrow pointed toward the vent pipe. (See Figure 12)Some installations require the vent fitting tobe installedwitha 20 to 30�� downward slope. (See Figures 8 -- Figure 11)

Figure 12Proper Sealing Procedure for

Combustion Blower

Vent Pipe (Top panel exit)

Rubber Coupling & Clamps90� Elbow

CombustionBlower


Vent Pipe(Side panel exit)


25--23--35

DRAIN SIDE VIEW

CL Rotatedownward20� to 30�

Joining Pipe and Fittings

Fire hazard.

Provide adequate ventilation and do NOTassemblenear heat sourceor open flame. DoNOTsmoke while using solvent cements and avoidcontact with skin or eyes.

Observe all cautions and warnings printed onmaterial containers to prevent possible death,personal injury and/or property damage.

!

This furnace is approved for venting with Schedule 40 PVC,CPVC, ABS, Cellular Core pipe fittings and SDR--26 PVC.

NOTE: All PVC, CPVC, ABS, and Cellular Core pipe fittings, sol-vent cement, primers and procedures MUST conform to Ameri-can National Standard Institute and AmericanSociety for Testingand Materials (ANSI/ASTM) standards.

� Pipe and Fittings -- ASTM D1785, D2241, D2466,D2661, D2665, F--891, F--628

� PVC Primer and Solvent Cement -- ASTM D2564

� Procedure for Cementing Joints -- Ref ASTM D2855

NOTE: In order to create a seal that allows future removal of pipe,RTV sealant MUST be used on the inlet pipe where it joins tothe furnace. PVC, CPVC, ABS, and Cellular Core pipe and ce-ment may be used on all other joints.

CAUTIONDo NOT use solvent cement that has become curdled,lumpy or thickened and do NOT thin. Observeprecautions printed on containers. For applicationsbelow 32� F., use only low temperature type solventcement.

1. Cut pipe end square, remove ragged edges and burrs.Chamfer end of pipe, then clean fitting, socket and pipejoint of all dirt, grease, or moisture.

18 440 01 2010 04

NOTE:Stir the solvent cement frequentlywhile using.Useanatu-ral bristle brushor thedauber suppliedwith thecement. Theprop-er brush size is one inch.

2. After checking pipe and socket for proper fit, wipe socketand pipe with cleaner-primer. Apply a liberal coat of primerto inside surface of socket and outside of pipe. DoNOT al-low primer to dry before applying cement.

3. Apply a thin coat of cement evenly in the socket. Quicklyapply a heavy coat of cement to the pipe end and insertpipe into fittings with a slight twisting movement until it bot-toms out.

NOTE:CementMUST be fluid while inserting pipe. IfNOT, recoatpipe.

4. Hold the pipe in the fitting for 30 seconds to prevent the ta-pered socket from pushing the pipe out of the fitting.

5. Wipe all excess cement from the joint with a rag. Allow 15minutes before handling. Cure time varies according to fit,temperature and humidity.

Connecting Vent Pipes and TerminationNOTE: Combustion air intake and vent MUST terminate in thesame atmospheric pressure zone. If installation is in a cold cli-mate (sustained temperatures below0�F), increase theminimumdistance between vent pipe and air intake from 8� to 18�.

CAUTIONMaintain a minimum of 36� between combustion airinlet and clothesdryer vent. Terminate the combustionair intake as far as possible from any air conditioner,heat pump, swimming pool, swimming pool pumping,chlorinator or filtration unit.


Inlet and outlet pipes may NOT be venteddirectly above each other


!

1. Install all couplings, nipples and elbows using proper pro-cedures for JoiningPipe andFittings andmaintain spac-ing between vent and combustion air piping as indicated inFigure 13 through Figure 20 .

Figure 13Sidewall Termination 12� or MoreAbove Snow Level or Grade Level

8� *MIN.

20�MAX

*18� Minimum for cold climates(substained below 0� F)

Horizontal Termination1. Cut two holes. 21/2� for 2� pipe, 3� for 21/2� pipe, or 31/2� for

3�pipe.DoNOTmake the holes oversized, or it will benec-essary to adda sheetmetal or plywoodplateon theoutsidewith the correct size hole in it.

2. Check hole sizes bymaking sure it is smaller than the cou-plings or elbows that will be installed on the outside. Thecouplings or elbows MUST prevent the pipe from beingpushed back through the wall.

3. Extend vent pipe and combustion air pipe through the wall3/4� to 1� and seal area between pipe and wall.

4. Install the couplings, nipple and termination elbows asshown and maintain spacing between vent and combus-tion air piping as indicated in Figure 13 and Figure 14.

Ametal shield is recommended 18� x 18�min. or 18�min. diame-ter around the vent termination at the exterior wall to protect thehouse exterior materials from flue product or condensation(freezing) damage.

Using Exterior Risers1. Install elbowsandpipe to formriser as shown inFigure 14.

2. Secure vent pipe to wall with galvanized strap or other rustresistant material to restrain pipe from moving.

3. Insulate pipe with Armaflex or equivalent moisture resis-tant closed cell foam insulation or Fiberglass insulation ifboxed in and sealed against moisture.

19440 01 2010 04

Figure 14Sidewall Termination with ExteriorRisers to Get Above Snow Level orGrade Level

8� *MIN.20�MAX

*18� Minimum for cold climates(substained below 0� F)

Vertical Termination

1. Figure 15 shows theproper installationand clearances forvertical vent termination. The vertical roof terminationshould be sealed with a plumbing roof boot or equivalentflashing. The inlet of the intake pipe and endof the exhaustvent must be terminated no less than 12� above the roof orsnowaccumulation level, and 12�away froma vertical wallor other protrusion.

2. If the vent system is installed in an existing chimney makesure clearances shown in Figure 15 are maintained. Hori-zontal section before the termination elbow can be ex-tended on the inlet air to provide necessary clearance.

Figure 15 Rooftop Termination

25--00--06

A

A

B

A = 12� Above roof or snow accumulation levelB = 8� Min., 20� Maximum, except in areas with extremecold temperatures (sustained below 0�F), the 18� Min.

Vent Termination Shielding

Under certainwind conditions somebuildingmaterialsmay beaf-fected by flue products expelled in close proximity to unprotectedsurfaces. Sealing or shielding of the exposed surfaceswith a cor-rosion resistantmaterial (such as aluminum sheeting)may be re-quired topreventstainingordeterioration.Theprotectivematerialshould be attached and sealed (if necessary) to the building be-fore attaching the vent terminal.

Multi Vent Termination ClearancesWhen two (2) or more furnaces are vented near each other, eachfurnace must be individually vented.

Two (2) vent terminations may be installed as shown inFigure 16, Figure 17, Figure 18, Figure 19, Figure 20 andFigure 21, but thenext vent terminationmustbeat least 36�awayfrom first 2 terminations. It is important that vent terminations bemade as shown to avoid recalculation of flue gases.

Figure 16 Concentric Vent and Combustion--Air Roof Termination

�A�

CombustionAir

Exhaust

12�� Min. Gradeor Snow Level

Dimension �A� is touching or 2� maximum separation.

Figure 17 Concentric Vent and Combustion--Air Sidewall Termination

�A�

Vent


25--22--02dVent

Combustion Air1�� Maximum

(TYP.)

Exhaust

�A�

�A�

Inlet

Figure 18 Sidewall Inlet Vent and Exhaust--Air Termination


12�� Min. Gradeor Snow Level

18�� Min. forCold Climates

(Sustained Below 0�� F)

8�� Min.20�� Max.

8�� Min.Exhaust

20 440 01 2010 04

Exhaust

8�� Min.

8�� Min.20�� Max.

Figure 19 Sidewall Inlet Vent and Exhaust--AirTermination with Exterior Risers


12�� Min.Grade orSnow Level

18�� Min. for Cold Climates(Sustained Below 0�� F)

Inlet

�A�

�A�

12�� Min.Grade orSnow Level

Exhaust

8�� Min.20�� Max.

Figure 20 Rooftop Inlet Vent and Exhaust--Air Termination

25--22--43

18�� Min. for Cold Climates(Sustained Below 0�� F)

Inlet

Figure 21Recommended Alternate Installa-tion for Sustained Cold Weather(--0�� F & below)

OVERHANG12�� MIN.

12�� MIN. Ground LevelOR Snow Level

INLET

EXHAUST

90��

Same JoistSpace

FRONT VIEW SIDE VIEW

25-23- 73

12�� MIN.

5. Gas Supply and Piping

Poison carbon monoxide gas, fire and explosionhazard.

Models designated for Natural Gas are to be usedwith Natural GasOnly, unless properly convertedto use with LP gas.


!

NOTE: The rating plate is stamped with the model number, gastype and gas input rating. In addition, models manufactured forsale in Canada have orifice size information stamped on the rat-ing plate.

Supply Pressure

Fire hazard.

Do NOT set input rating above that shown onrating plate.

Failure to properly set input pressure can result indeath, personal injury and/or property damage.

!

1. Supply pressure can be checked using the 1/8� NPT porton the supply side of the gas valve.

2. Gas input to burners MUST NOT exceed the rated inputshown on rating plate.

3. DoNOT allowminimumgas supply pressure to vary down-ward. Doing so will decrease input to furnace. Refer toTable 5 for normal gas supply and manifold pressures.

21440 01 2010 04

Table 5 Gas Pressures Below 2000 Ft.GasType

Supply Pressure ManifoldPressureType

Recom- Max MinPressure

Recom-mended

Max. Min.Hi Fire Lo Fire

Natural 7�(1.7 kPa)

14�(3.5 kPa)

4.5�(1.1 kPa)

3.5�(0.9 kPa)

1.7�(0.5 kPa)

LP 11�(2.7 kPa)

14�(3.5 kPa)

11�(2.7 kPa)

10�(2.5 kPa)

4.9�(1.3 kPa)

Important Notes

� With Propane gas, the rated input is obtained when theBTU content is 2,500 BTU per cubic foot and manifoldpressure set at 10�� W.C.

� If Propane gas has a different BTU content, orifices MUSTbe changed by licensed Propane installer.

� Measured input can NOT exceed rated input.

� CombustionAirBoxCoverMUSTberemovedwhenadjust-ing manifold pressure.

� Any major change in gas flow requires changing burnerorifice size.

MANIFOLD PRESSURE AND ORIFICE SIZE FOR HIGH ALTITUDE APPLICATIONS

Table 6 High Altitude Pressure Chart2000--8000 ft. (Natural Gas)

Heat Val eElevation Above Sea Level

Heat ValueBtu/Cu.Ft. 0--1999 2000--2999 3000--3999 4000--4999 5000--5999 6000--6999 7000--7999Btu/Cu.Ft.

High Low High Low High Low High Low High Low High Low High Low

800 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7

850 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7

900 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.4 1.7

950 3.5 1.7 3.5 1.7 3.5 1.7 3.5 1.7 3.3 1.6 3.2 1.6 3.1 1.5

1000 3.5 1.7 3.4 1.7 3.3 1.6 3.2 1.5 3.0 1.5 2.9 1.4 2.8 1.4

1050 3.2 1.6 3.1 1.5 3.0 1.5 2.9 1.4 2.7 1.3 2.6 1.3 2.5 1.2

1100 2.9 1.4 2.8 1.4 2.7 1.3 2.6 1.3 2.5 1.2 2.4 1.2 2.3 1.1

Orifice Size #42 #42 #42 #42 #42 #42 #42

Gas Supply PressureGas supply pressure should be within minimum and maximumvalues listedon ratingplate.Pressuresareusually setbygassup-pliers.

Manifold Gas Pressure Adjustment (Hi & Lo Fire)NOTE:Make adjustment tomanifold pressurewith burners oper-ating.

Fire or explosion hazard.

Turn OFF gas at shut off before connectingmanometer.

Failure to turn OFF gas at shut off beforeconnecting manometer can result in death,personal injury and/or property damage.

!

1. Remove the burner compartment door.

2. Connect manometer to the tapped opening on the outletside of gas valve. Use a manometer with a 0 to 12� mini-mum water column range.

3. Turn gas ON. Operate the furnace on high fire by using ajumper wire on the R to W1 & W2 thermostat connectionson the fan board.

4. Remove the adjustment cover on the gas valve. Turn ad-justing screw counterclockwise to decrease the manifoldpressure and clockwise to increase. See Figure 38.

5. Set the manifold pressure to value shown in Table 5 orTable 6.

6. Operate the furnace on low fire by using a jumper wire onthe R to W1 thermostat connections on the fan board.Note: The fourth (4th) DIP switch should be in the on posi-tion to set the low fire manifold pressure. (See wiring di-gram)

7. Repeat steps 4 and 5 for low fire operation.8. When themanifold pressures are properly set, replace the

adjustment screw covers on the gas valve.9. Remove the jumperwires from the thermostat connections

on the fan board. Remove manometer and replace plug ingas valve.

10. Reture fourth (4th) DIP switch to previous setting.11. Replace the burner compartment door.

22 440 01 2010 04

General Derating Rules1. For operation with natural gas at altitudes above 2,000�,

orifice change and/or manifold pressure adjustment maybe required to suit gas supplied. Checkwith gas supplier. Iforifice sizing is needed, it should be based on reducing theinput rating by 2% (natural) or 4% (LP) for each 1,000�above sea level. See Table 6 and Figure 22 for requiredpressure change and/or orifice change for high altitudes.

2. ForoperationwithLPgasataltitudesabove2,000�, gasori-ficesMUST be changed and manifold pressure MUST bemaintained as perTable 5.Orifice sizes for 0--2000�abovesea level are #54. 2000--7000� above sea level, use #55.7000--8000� above sea level, use #56orifices. Orifices canbe ordered through your distributor. (See Figure 22)

NOTE: The derating of these units at 2% (Natural) and 4% (L.P.)has been tested and approved by CSA.

High Altitude Air Pressure SwitchAltitudes over 4,000� require a different air pressure switch thantheone installedat the factory.Checkparts list for pressureswitchand consult your distributor for part number and availability. InCanada, provincial codes may govern installation of switch.Check with governing authorities.

Changing Orifices for High Altitude

Electrical shock, fire or explosion hazard.

Turn OFF electric power (at disconnect) and gassupply (at manual valve in gas line) wheninstalling orifices. Installation of orifices requiresa qualified service technician.

Failure to properly install orifices can result indeath, personal injury and/or property damage.

!

NOTE: Main burner orifices can be changed for high altitudes.

1. Disconnect gas line from gas valve.

2. Remove manifold from furnace.

3. Remove the orifices from the manifold and replace themwith properly sized orifices.

4. Tighten orifices so it is seated and gas tight. (SeeFigure 22)

Figure 22 Changing Orifices

11/8� to 13/16�

Measure from face of orificeto the back side of themanifold.

5. Reinstall manifold. Ensure burners do NOT bind on neworifices.

23440 01 2010 04

Use elbows and 3�� pipenipple to connect valve topiping when using rightside gas pipe entry.

* Union may be installed inside the cabinet when necessary because of clearances.

Figure 23 Typical Gas Piping for Upflow

Drip Leg and Union, Union* should be outside thecabinet. Manual shut--off valve MUST be upstreamof dripleg, union, and furnace.

LP Low pressureswitch. Optionalon some models.

25--23--37

Gas Pipe Grommet(Single Pipe)

3�� pipe nipple

25--23--84

Natural Gas Input Rating CheckNOTE: The gas meter can be used to measure input to furnace.Rating is based on a natural gas BTU content of 1,000 BTU�s percubic meter. Check with gas supplier for actual BTU content.1. Turn OFF gas supply to all appliances and start furnace.

Use jumper wire on R to W1 and W2 for Hi fire.2. Time how many seconds it takes the smallest dial on the

gas meter to make one complete revolution. Refer to Ex-ample.

3. Repeat steps 1 and 2 with jumper wire on R to W2 for lowfire.NOTE: Fourth (4th) dip switch must be in �ON� position.(See Furnace Wiring Diagram). Return fourth (4th) dipswitch to previous setting after check.

ExampleNatural GasBTU Content

No. of SecondsPer Hour

Time Per CubicFoot in Seconds

BTU PerHour

1,000 3,600 48 75,000

1,000 x 3,600 � 48 = 75,000 BTUH

4. Relight all appliances and ensure all pilots are operating.

NOTE: If meter uses a 2 cubic foot dial, divide results (seconds)by two.

24 440 01 2010 04

Use elbows and 3�� pipe nipple to connectvalve to piping when using left side gaspipe entry.

*Union may be installed inside the cabinet when necessary because of clearances.

Figure 24 Typical Gas Piping for Downflow

Drip Leg and Union, Union* should be outsidethe cabinet. Manual shut--off valve MUST beupstream of dripleg, union, and furnace.

LP Low pressureswitch. Optional LPconversion.

Gas Pipe Grommet(Single Pipe)

25--23--39

Gas Piping RequirementsNOTE: The gas supply line must be installed by a qualified ser-vice technician inaccordancewithall building codes, (In thestateof Massachusetts, gas supply connections MUST be performedby a licensed plumber or gas fitter).

1. Properly size gas pipe to handle combined appliance loador run gas pipe directly from gasmeter or LP gas regulator.Refer to NFGC and ANSI Z223.1 for proper gas pipe size.

2. Install correct pipe size for run length and furnace rating.

3. Measure pipe length from gas meter or LP second stageregulator.

NOTE: Refer to Figure 23 or Figure 24 for the general layout atthe furnace. The rules listed apply to natural and LP gas pipeinstallations.

NOTE:On theDualCertifiedorDirectVentmodels, install thegaspipe grommet to the furnace side panel with the gas pipe entry. Ifneeded, remove the 2� hole plug and relocate to the open hole inthe furnace side panel.

4. Use black iron or steel pipe and fittings or other pipe ap-proved by local code.

NOTE: The use of copper tubing for gas piping is NOT approvedby the state of Massachusetts.

5. Useground joint unionsand install a drip legno less than3�long to trap dirt andmoisture before it can enter gas valve.

6. Use two pipe wrenches when making connections to pre-vent gas valve from turning.

7. Install a manual shut--off valve external to furnace casingand tighten all joints securely.

Additional LP Connection Requirements

1. Have a licensed LP gas dealer make all connections atstorage tank and check all connections from tank to fur-nace.

2. If copper tubing is used, itMUST comply with limitation setin National Fuel Gas Code or CGA codes.

3. Two--stage regulation of LP gas is recommended.

Final Check1. The furnace and its individual shut--off valvemust be discon-

nected from the gas supply piping systemduring any pres-sure testing of that system at test pressures in excess of1/2� PSIG.

The furnace must be isolated from the gas supply pipingsystem by closing its individual manual shut--off valve dur-ing any pressure testing of the gas supply piping systemattest pressures equal to or less than 1/2� PSIG.

2. Test all pipes for leaks.

3. Gas pressure MUST NOT exceed 1/2� PSIG to gas valve.Checking gas piping above 1/2� PSIG requires the furnaceand manual shut-off valve to be disconnected during test-ing.

4. Apply soap suds (or a liquid detergent) to each joint.Bubbles forming indicate a leak.

5. Correct even the smallest leak at once.

6. If orifices were changed, make sure they are checked forleakage.

25440 01 2010 04

6. Electrical Wiring

Electrical shock hazard.

Turn OFF electric power at fuse box or servicepanel before making any electrical connectionsand ensure a proper ground connection is madebefore connecting line voltage.

Failure to do so can result in death, personal inju-ry and/or property damage.

!

Power Supply WiringThe furnace MUST be electrically wired and grounded in accor-dance with local codes, or in the absence of local codes with thelatest editionofTheNationalElectricCode,ANSINFPA70and/orThe Canadian Electric Code CSA C22.1.

Field wiring connections must be made inside the furnace con-nection box. A suitable strain relief should be usedat the point thewires exit the furnace casing.

Copperconductorsmustbeused. Line voltagewires shouldbesized for the inputampsstatedon the ratingplate. Furnaceshouldbe connected to its own separate circuit.

ThermostatThe2--stage furnacecontrolwill operatewith either a single stageor a two stage heating thermostat and will provide 2--stage heat-ing operation. For single stage thermostat installations, theRandW wires from the thermostat connect to the R and W1 connec-tions on the furnace control. Note: The fourth (4th) DIP switchmust be in the off position, failure to change DIP switch will resultin Lo FireONLYoperation. (See furnace wiring digram) See �Fur-naceWiringDiagram� for switch settings.Failure tosetDIPswitchwill result in Lo fire operation ONLY with single stage thermostat.During operation, the furnace will operate on low fire for 12minu-tesIf the heat request exists for more than 12 minutes. If the heatrequest exists formore that 12minutes, the furnacewill automati-cally shift to the high fire mode for the remaining duration of theheating cycle. For two stage thermostat installations, the R, W1andW2 wires from the thermostat connect to the R, W1 andW2connections on the furnacecontrol. Duringoperation, the furnacewill shift from low fire to high fire as requested by the thermostat.The thermostat heat anticipators should be adjusted to a .10 set-ting for both types of thermostats.

Low voltage connections to furnace must be made on terminalboard to fan control.

Optional EquipmentAll wiring from furnace to optional equipment MUST conform tolocal codes or, in the absenceof local codeswith the latest editionof The National Electric Code, ANSI NFPA 70 and/or The Cana-dian Electric Code CSA C22.1. Install wiring in accordance withmanufacturer�s instructions. The wiring MUST have a minimumtemperature rating of 105� C. codes or, in the absence of localcodes, the applicable national codes. Install wiring in accordancewith manufacturer�s instructions.

Humidifier/Electronic Air CleanerThe furnace is wired for humidifier and/or electronic air cleanerconnection.

CAUTIONDo NOT exceed 115V/0.8 amp. maximum current loadfor both the EAC terminal and the HUM terminalcombined.

NOTE: The humidifier will be powered when the furnace is firedand thecirculatingair blower comeson.Theelectronic air cleanerwill be powered anytime the air circulating blower is energizedduring the heat mode. However, the electronic air cleaner isNOTenergized during continuous fan operation controlled by theelec-tronic fan control.

Figure 25 Electrical Connections

NOTE: Junction Box can bemounted to either the left orright side.

25--23--42

W2

W2

W2

Dehumidification -- Variable Speed ONLY (*9MPV)The fan control is wired for 24 VAC normally open (N/O) dehumi-distat connection.Connect dehumidistat to theR terminal and the1/4� male quick connect Y2 terminal on the fan control (SeeFigure 26 and �Furnace Wiring Diagram�). A 20% reduction ofcooling airflowwill occurwhen theY2dehumidistat terminal is en-ergized during a call for cooling from the thermostat.

Fan ControlThe fan control is preset at the factory with a fixed blower ONdelay of 30 seconds in the heating mode. The blowerOFF timingis preset at 140 seconds. If desired, the fanOFF delay can be re-set toobtain the longestdelay timeswhilestillmaintainingcomfortlevels. See �Furnace Wiring Diagram� .

26 440 01 2010 04

Control Center FuseThe 24V circuit contains a 5--amp, automotive--type fuse locatedon fan timer board. (See Figure 26) Any electrical shorts of 24Vwiring during installation, service, or maintenance may causefuse to blow. If fuse replacement is required, use only a fuse ofidentical size (5 amp.)

Fan Timer ConnectionsFigure 26

Dip SwitchSee �WiringDiagram� forswitch settings

FUSE

7. Ductwork and Filter


Do NOT draw return air from inside a closet orutility room. Return air duct MUST be sealed tofurnace casing.

Failure to properly seal duct can result in death,personal injury and/or property damage.

!

InstallationNOTE: Design and install air distribution system to comply withAir Conditioning Contractors of America manuals and/or NFPApamphlets 90A and 90Bor other approvedmethods that conformto local codes and good trade practices.

1. When furnace supply ducts carry air outside furnace area,seal return air duct to furnace casing and terminate ductoutside furnace space .

2. Install air conditioning cooling coil (evaporator) on outletside of furnace.

3. For furnaces installed without a cooling coil it is recom-mended that the outlet duct be provided with a removableaccess panel. This panel should be accessible when thefurnace is installed so the exterior of the heat exchangercan be viewed for inspections. The access panelMUSTbesealed to prevent leaks.

4. If separate evaporator and blower units are used, installgood sealing dampers for air flow control. Chilled air goingthrough the furnacecouldcausecondensationandshortenthe furnace life.

NOTE: Dampers (field supplied) can be either automatic ormanual. Manually operated dampers MUST be equipped with ameans to prevent furnace or air conditioning operation unlessdamper is in the full heat or cool position.


Cool air passing over heat exchanger can causecondensate to form resulting in heat exchangerfailure.

This could result in death, personal injury and/orproperty damage.

!

ConnectionsNOTE:Onupflow installations, return air can enter througheitherside,bothsides,or thebottom.Onhorizontal or downflow installa-tions the returnairmust enter through theknockout opening in thelower panel of the furnace. Return air can not enter through rearof the furnace.When the furnace is located in an area near or ad-jacent to the living area, the system should be carefully designedwith returns to minimize noise transmission through the returngrille. Any blowermoving ahigh volumeof airwill produceaudiblenoise which could be objectionable to when the unit is locatedvery close to living areas. It is advisable to route the return airducts under the floor or through the attic.

27440 01 2010 04

1. For side connections using a 16�x 25� filter, cut out the em-bossed area shown in Figure 27. This will provide a 141/2�x 221/2� approximate opening.

Figure 27 Side Return Air Cutout

Embossed Areaon Side of Furnace

A = 141/2� Height of Cutout for 16� x 25� FilterB = 221/2� Width of Cutout for 16� x 25� Filter

A

FurnaceBottom

B

NOTE: Furnaces with 5 TONS cooling rating require two(2) sidereturns or one side return with bottom return.

2. Bottom returns can be made by removing the knockoutpanel in the furnace base. Do NOT remove knock-out ex-cept for a bottom return.

3. Installation of locking-type dampers are recommended inall branches, or in individual ducts to balance system�s airflow.

4. Non-combustible, flexible duct connectors are recom-mended for return and supply connections to furnace.

5. If air return grille is located close to the fan inlet, install atleast one, 90� air turn between fan and inlet grille to reducenoise.

NOTE: To further reduce noise, install acoustical air turningvanes and/or line the inside of duct with acoustical material.

SizingExisting or new ductwork MUST be sized to handle the correctamount of airflow for either heating only or heating and air condi-tioning.

Insulation1. Insulate ductwork installed in attics or other areasexposed

to outside temperatures with a minimum of 2� insulationand vapor barrier.

2. Insulate ductwork in indoor unconditioned areas with aminimum of 1� insulation with indoor type vapor barrier.

FiltersA Filter must be used:

Filtersarenot suppliedwith these furnaces, but canbepurchasedfrom dealer.

Use either filter type:

� Washable, high velocity filters are based on amaximumair flow rating of 600 FPM.

� Disposable, lowvelocity filters are basedonamaximumair flow of 300 FPM when used with filter grille.

NOTE: Disposable, low velocity filters may be replaced withwashable, high velocity filter providing they meet the minimumsize areas.Washable, high velocity filters can be replacedONLYwith same type and size.

Figure 28 Side Mounted Filter Rack

25-20-90

Filter Installation using Filter RackWhen installing or removing a bottommounted filter, slide the twoside filter clips to the back of the furnaceBEFORE installing or re-moving.Thiswill allow the filter to clear the front raisededgeof thefurnace. Insert filter into sideclips first andpush filter backuntil it isfully engaged intoback clip.When filter is in place, slide clipsbackinto place midway on filter as shown in Figure 29.

Figure 29 Bottom Mounted Filter Rack

AW3192

Slide filter clips towards back before removing

Refer to Figure 30 and for guidelines to install filters. Furnaceswhich require larger filter media and have limited clearances onone side of furnace, require a standoff filter rack, see Figure 30,available from your distributor.

28 440 01 2010 04

Figure 30 Standoff Filter Rack

25--21--45a

Using OptionalStandoff Filter

Rack

CAUTIONIf filters are only suitable for heating application,advise homeowner that filter size may need to beincreased if air conditioning is added.

Addition Of Air ConditioningWhen a refrigeration coil is used in conjunction with this unit, itmust be installed on the discharge side of the unit to avoid con-densationon theheatexchanger.Thecoil installation instructionsmust be consulted for proper coil location and installation proce-dures. With a parallel flow arrangement, dampers must beinstalled to prevent chilled air from entering the furnace. If manu-ally operated dampers are used, they must be equipped with ameans to prevent operation of either unit unless the damper is infull heat or full cool position.

A 3� clearance is required on the right side of the furnace in orderto run the condensate drain line. Copper, iron or plastic tubingmay be used for the condensate drain line.

Downflow Furnace InstallationNon-Combustible Floor InstallationFabricate a plenum to the dimensions given in Figure 3, for thefurnace outlet. Plenum should be flanged, approximately 3/4� forsupport.

Note: The three(3) screws in the top panel of the furnace next tothe duct flangeMUST be removed to provide serviceability of theprimary heat exchangers in the downflow installation

1. Position plenum through the floor and set the furnace overtheopening in the floor. If necessary, grout around thebaseto seal air leaks between the base and the floor.

Combustible Floor Installation

Fire Hazard.

Place furnace on noncombustible subbase ondownflow applications, unless installing onnon--combustible flooring.

Failure to install unit on noncombustiblesubbase can result in death, personal injuryand/or property damage.

!

Subbase for Combustible Floor

NOTE:The three(3) screws in the top panel of the furnace next tothe duct flangeMUST be removed to provide serviceability of theprimary heat exchangers in the downflow installation

Note: When using the subbase for combustible floors, the dis-charge air duct flanges on the furnace MUST be broken down toprovide proper fit up to the subbase. Use duct pliers to bend theduct flanges flat onto the furnace casing. DO NOT bend the ductflanges inward (toward the heat exchangers) as air flow restric-tions may occur.

The Subbase for Combustible Floors MUST be used when adownflow furnace is set onacombustible floor, evenwhen the fur-nace is installed on a coil box.

1. Cut the opening in the floor according to Table 7. The holein the floor must be cut to the dimensions listed in Table 7since the base is equipped with locating tabs that centerthe base over the opening.

The opening in the base is 11/4� shorter and 11/8� narrower thanthe recommended size of the opening in the floor. This is done tomaintain clearance between the floor and the plenum.

2. Fabricate the plenum to the dimensions given in Table 7.Note that the dimensions given are outside dimensions.

29440 01 2010 04

Table 7 Subbases for Combustible Floors Dimensions

Subbase for CombustibleFloors Part Number

Subbase for CombustibleFloor Dimensions Opening In Floor Opening In Base

For PlenumTypical PlenumDimensions

Floors Part NumberH* J* K** L M N P R S T

Furnace SubbaseNAHH001SB 1511/16 283/4 149/16 16 161/4 145/8 15 131/2 15 131/2

NAHH002SB 195/16 283/4 183/16 16 161/4 181/4 15 171/8 15 171/8

NAHH003SB 225/16 283/4 2113/16 16 161/4 217/8 15 193/4 15 193/4

NAHH010SB 243/4 209/16 239/16 161/4 161/4 235/8 15 221/2 15 221/2Subbase forCoil Cabinets

NAHH004SB 1511/16 209/16 149/16 161/4 161/4 145/8 15 131/2 15 131/2

NAHH005SB 195/16 209/16 183/16 161/4 161/4 181/4 15 171/8 15 171/8

NAHH006SB 23 209/16 2113/16 161/4 161/4 217/8 15 193/4 15 193/4

NAHH009SB 2411/16 283/4 239/16 16 161/4 235/8 15 221/2 15 221/2* Outside Dimension** Base Spacer Side To Side

3. Set the base over the opening in the floor, centering it overthe opening. Fasten the base to the floor with screws ornails. See Figure 31, Figure 32 and Figure 33.

T S

H J

1�

2�

N M

R

PL

2�

25--20--46

Plenum

CombustibleFloor Base

Furnace SubbaseFigure 31

A

A = 4 1/4� Minimum clearance from back of holeto wall or other obstruction.

Hole inFloor

K

T S

H J

1�

2�

N M

K R

PL

2�

25--20--46b

Plenum

Figure 32 Coil Cabinet Subbase

A

A = 4 1/4� Minimum clearance from back of hole to wall or other obstruction.

Hole inFloor

4. Drop the plenum through the opening in the base. Theflange of the plenum should rest on top of the subbase.

5. Position furnace or coil cabinet and furnace on subbase soit aligns between the locating tabs.

25--20--46a

Furnace

Wood Screw Plenum

Wood Floor

Insulation ofCombustibleFloor Base

Figure 33 Setting the Subbase

This subbase for combustible floors has been designed so thatthe height of the subbase raises the downflow coil off the floor toallow easy installation of the condensate drain. See Figure 34.

30 440 01 2010 04

Condensate Line Raised by BaseFigure 34

25--20--52

8. Checks and AdjustmentsStartupNOTE: Refer to the start--up procedures in the �User�s Informa-tion Manual� or to the �Operating Instructions Label� on the fur-nace.

CAUTIONIf any sparks, odors or unusual noises occur,immediately shut OFF power to furnace. Check forwiring errors or obstruction to blower.

Gas Supply PressureGas supply pressure should be within minimum and maximumvalues listedon ratingplate.Pressuresareusually setbygassup-pliers.

Manifold Gas Pressure AdjustmentNOTE:Make adjustment tomanifold pressurewith burners oper-ating.

Fire or explosion hazard.

Turn OFF gas at shut off before connectingmanometer.

Failure to turn OFF gas at shut off beforeconnecting manometer can result in death,personal injury and/or property damage.

!

1. Remove the burner compartment door.

2. With gas OFF, connect manometer to tapped opening ongas valve. Use manometer with a 0 to 15� water columnrange.

3. Turn gas ON and remove adjustment screw cover on gasvalve. Turn counterclockwise to decrease pressure andclockwise to increase.

4. For altitudes up to 2000�, set pressure to value shown inTable 5, � 0.3� (8mm) water column. For altitudes of 2000�to 8000�, see Section 5 for correct pressure setting.

Adjust Pilot BurnerThe furnace has a pilot flame to light the main burner. The flameshould surround 3/8� to 1/2�of the flamesensor.SeeFigure 35.Toadjust, remove cap from pilot adjusting screw on gas valve. Turnscrew counterclockwise to increase or clockwise to decreaseflame as required. Replace adjusting screw cap.

Pilot BurnerFigure 35

Proper FlameAdjustment

Flame Sensor

Hot SurfaceIgniter

10--11--65

3/8� to 1/2�

Main Burner Flame CheckAllow the furnace to run approximately 10 minutes then inspectthe main burner and pilot flames. See Figure 36.

Check for the following (Figure 36):� Stable and blue flames. Dust may cause orange tips orwisps of yellow, but flamesMUST NOT have solid, yel-low tips.

� Flames extending directly from burner into heat ex-changer.

� Flames do NOT touch sides of heat exchanger.

If any problemswithmain burner flames are noted, it may be nec-essary to adjust gas pressures, or check for drafts.

31440 01 2010 04

Main Burner

Burner Face

10--10--78

Figure 36

Temperature Rise CheckTheblower speedMUSTbeset togive thecorrect air temperaturerise through the furnace as marked on the rating plate for bothhigh fire and low fire operation. Temperature rise is the differencebetween supply and return air temperatures.

To check temperature rise,use the following procedure:

1. Place thermometers in supply and return air registers asclose to furnace as possible, avoiding direct radiant heatfrom heat exchangers.

2. Operate furnace on high fire for 10minutes with all the reg-isters and duct dampers open by using a jumper wire on Rto W1 and W2 thermostat connections on the fan board.Note: The fourth (4th) DIP switch should be in the on posi-tion. (See furnace wiring digram)

3. Take readings and compare with range specified on ratingplate.

4. If the temperature rise is not in thecorrect range, theblowerspeed must be changed. A higher blower speed will lowerthe temperature rise. A lower blower speed will increasethe temperature rise.

5. Repeat steps 2 thru 4with the furnace operating on low firefor 10 minutes by using a jumper wire on the R to W1 ther-mostat connections on the fan board.

6. Remove the jumper wire after the adjustments are com-plete. Return fourth (4th) to previous setting.

Changing Blower Speed (*9MPT Models)


Turn OFF power to furnace before changing speedtaps.

Failure to do so can result in death and/or personal in-jury .

!

NOTE: The speed taps that themanufacture sets from the factoryfor this product are based on a nominal 400 CFM per ton coolingand the basic mid range on the temperature rise for heating.

Since the manufacturer cannot establish the static pressure thatwill be applied to the unit, it is the responsibility of the installerdealer/contractor to select the proper speed taps for the applica-tion when the unit is installed.

If it is necessary to change speeds, refer to steps below.

1. Refer toFurnaceWiringDiagram for locationof theheatingand cooling speed taps located on the electronic fan con-trol as well as location of unused blower motor speedleads. Use the chart (Table 8) to determine the blowermo-tor speed settings.

Table 8 Blower Speed Chart

Wire Color Motor SpeedBlack High

Orange* Med--HighBlue MediumRed Low

* Med--High speed may not be provided on all models.

2. Change the heat or cool blower motor speed by removingthe motor lead from the �Heat� or �Cool� terminal and re-place it with the desired motor speed lead from the �Un-used Motor Lead� location. Connect the wire previouslyremoved from the �Heat� or �Cool� terminal to the vacated�Unused Motor Lead� terminal.

3. If the same speed must be used for both heating and cool-ing, remove the undesired motor speed lead from the�Heat� or �Cool� terminal and connect that lead to theopen terminal at �Unused Motor Lead� location. Attach ajumper between the �Heat� and �Cool� terminals and theremaining motor speed lead.

Note: For motors with (4) speed leads, it will be necessaryto tape off the terminal of the motor speed lead removedfrom the �Heat� or �Cool� terminal with electrical tape sincean open terminal will not be available at the �Unused Mo-tor Lead� location.

Continuous Fan OperationA terminal is provided on the electronic fan control located in thecirculating blower compartment for operation of the continuousfan option. This connection is intended for the low speed motortap, and has a lower contact rating (8 amps) than the heat andcool taps. When the low speed blower lead is connected to thisterminal, this will provide low speed blower operation wheneverthe other two speeds (Heat or Cool) are not energized.

Thoroughly check the system after modification to ensure theproper operation of the circulating air blower in all modes of op-eration.

Separate speed selections for Heat, Cool, andContinuous FanConnect low speed lead from circulating motor to the �Cont.� ter-minal at the electronic fan control. The appropriate motor leadsshould already be connected to the �Heat� and �Cool� terminals.

Heating and Continuous Blower Speed the SameIf it is necessary to operate the heating speed and continuousblower speedusing thesameblowerspeed, connecta jumperbe-tween the �Heat� and �Cont.� terminals on the electronic fan con-trol.

Note: There should be only ONE motor lead going to the �Heat�and �Cont.� terminals.

32 440 01 2010 04

Changing Blower Speed (*9MPV Models)


Turn OFF power to furnace before changing speedtaps.Failure to do so can result in personal injury and/orproperty damage.

!

NOTE: The blower speeds that the manufacturer sets from thefactory for this product are based on a nominal 400 CFM per toncooling and the mid range on the temperature rise for heating.Since the manufacturer cannot establish the static pressure thatwill be applied to the unit, it is the responsibility of the installerdealer/contractor to select the proper speed taps for the applica-tion when the unit is installed.If it is necessary to change speeds, refer to steps below.1. The 115 VAC power supply to the furnace must be turned

OFF before making adjustments to the motor.

2. Theheating, coolingandcontinuousblower speedscanbeadjusted by changing the switch settings that are locatedon the motor control (see Figure 37). Switches #1 and #2adjust the continuous blower speeds. Switches #3, #4 and#5 adjust the heating speeds. Switches #6, #7 and #8 ad-just thecooling speed.See the �TechnicalSupportManual�for the switch settings for the desired airflow rates for theinstallation.

Blower Motor ControlFigure 37

*EXAMPLECooling Airflows Switches6, 7 & 8:

000 3.5 Ton001 3.0 Ton010 2.5 Ton011 2.0 Ton

*See �Technical SupportManual� for correct airflowrates.

0 1 0

INPUTSIGNAL ORTHERMOSTATCONNECTIONS

9. Furnace Maintenance

CAUTIONIt is recommended that the furnace be inspected andserviced on an annual basis (before the heatingseason) by a qualified service technician.

See �User�s Information Manual� and the �ServiceManual�.

10. Sequence of Operation & Diagnostics

The following is the normal operating sequence for the 2--stage control system.

Cooling (Y) Request:24 VAC signals applied to Y & G terminals of EFT (electronic fan timer) control.� Cool motor speed energized after 5 second Cool Fan On Delay time.

Y & G signals removed from EFT.� Cool motor speed de--energized after 60 second Cool Fan Off Delay time.

33440 01 2010 04

Cooling (Y) and dehumidification (Y2) requests:� 24 VAC signals applied to Y, Y2 & G terminals of EFT (electronic fan timer) control.� Same operation as the cooling (Y) request, except the cooling speed is reduced 20% to compensate for high humidity conditions duringcooling operation. The cooling speed returns to the normal setting after the Y2 signal is removed.

Circulating Fan (G) Request:24 VAC signals applied to G terminals of EFT control.� Low motor speed energized without delay.

G signal removed from EFT.� Low motor speed de--energized without delay.

NOTE1) Furnaces with DC blower motors run a low circulating fan speed in response to G request.

NOTE2) Furnaces with PSC blower motors de--energize the Low Heat fan speed during the heat exchanger warm--up period on acall for Heating that occurs during a G request.

NOTE3) Heating or Cooling requests received during a Fan request cause the fan speed to change to the appropriate heat or coolspeedafter the selectedFanOnDelay timeexpires. The fan returns to circulating speedafter the selectedFanOffDelay timeexpiresfollowing loss of the Heating or Cooling request.

Heating (W1) Request (single stage thermostat operation, 4th DIP switch must be in off position) (see furnacewiring diagram):

24 VAC signals applied to W1 terminal of EFT control.� Inducer motor turns on at high speed.� The high fire solenoid energizes.� Following a 3 second prepurge delay, the pilot valve opens and the ignitor begins to warm up.� After the pilot lights, the main burners energize and light (burners now at high fire rate).� Timed from the opening of the main gas valve, the control will delay the selected Heat Fan On Delay time before switching the

inducer to low speed, de--energizing the high fire solenoid and the fan switches to Low Heat speed.� Timed from initial application of the Heating request, if the W1 request is still present after the selected Low Fire Delay time

expires (12 minutes), the inducer switches to high speed, the high fire solenoid energizes and the fan switches to High Heatspeed.

W1 signal removed from EFT.� The gas valve de--energizes and the main burners go out.� The inducer runs at its present speed for a 5 second postpurge period.� The fan switches to (or stays at) Low Heat speed.� Timed from the gas valve de--energizing, the Low Heat fan speed de--energizes after the selected Heat Fan Delay time expires.

NOTE4) If a newHeating request arrives while the control is waiting in the Heat Fan Off Delay time, the fan speed switches to HighHeat until the Heat Fan Off Delay expires or the Heat Fan On Delay expires for the new Heating request.

Heating Request (two stage thermostat operation, 4th DIP switch must be in on position) (see furnace wiringdiagram):

24 VAC signals applied to W1 terminal of EFT control.� Same response as single stage thermostat operation described above except the control will not go to high fire, High Heat fan

speed unless a W2 signal is applied.

24 VAC signals applied to W1 and W2 terminals of EFT control.� Same light--off routine as described for the signal stage thermostat operation except that at the endof the selectedHeat FanOnDelay, the

inducer remains on high fire, the high fire solenoid remains energized and the High Heat fan speed energizes.

NOTE5) TheEFTcontrol respondswithout delay to the presence or loss ofW2 (withW1 constant).W1&W2 results in high inducer,high fire and High Heat fan speed. W1 only results in low inducer, low fire and Low Heat fan speed.

34 440 01 2010 04

Heating Request with Gas Supply Line Shut Off:24 VAC signals applied to W1 terminal of EFT control.� Inducer motor turns on at high speed.� The high fire solenoid energizes.� Following a 3 second prepurge delay, the pilot valve opens and the ignitor begins to warm up.� The ignitor glows red--hot for 30 seconds, then turns off.� The igniter stays off for 25 seconds, then begins to warm--up again.� The igniter glows red--hot for 30 seconds, then turns off.� The pilot valve closes 3 seconds after the igniter de--energizes.� The inducer de--energizes 5 seconds after the pilot valve closes.� The SmartValve proceeds to soft lockout and flashes error

code 6.� The control exits soft lockout after 5 minutes and begins another

ignition sequence.

Gas Valve Diagnostic Codes (See Figure 38)OFF = Control not poweredHeartbeat = Normal Operation (Standby or call for heat)1 Flash = Not used2 Flashes = Low Pressure switch closed when should be open3 Flashes = Low Pressure switch circuit was still sensed as open 30 seconds after the inducer was energized. System

is in 5 minute delay mode, with inducer off. After 5--minute delay, a new ignition sequence will be initiated.(Note: SV9541Q On/Off switch in off position during a call for heat will generate this diagnostic code)

4 Flashes = Limit switch string open5 Flashes = Flame sensed out of sequence -- Flame signal still present.6 Flashes + 1 Note 1 = Soft Lockout --Maximum retry count exceeded (failed to light within 4 trials for ignition)6 Flashes + 2 Notes 1,2 = Soft Lockout --Maximum recycle count exceeded -- Last failurewas FlameSense Lost DuringRun,Cycling

Pressure Switch or Blocked Condensate.6 Flashes + 3 Notes 1,2 = Soft Lockout --Maximum recycle count exceeded -- Last failure was Airflow Proving Circuit Opened

During Run6 Flashes + 4 Notes 1,2 = Soft Lockout --Maximum recycle count exceeded -- Last failure was Limit Circuit Opened During Run7 Flashes = Soft Lockout Due to Limit Trips Taking Longer than 2 minutes to Reset; Auto Reset After 1 Hour if

Call for Heat Still Present. Reset by Cycling Call for Heat at Any Time.8 Flashes = High Pressure Switch closed when sould be open.9 Flashes = High Pressure Switch open when sould be closed.

NOTE1:The6+Xdesignation indicatesacombinationof flashcodes:6 flashesshows thecontrol is in soft lockout, followedbyX flashesto indicate the reason the controlwent into soft lockout.When the6+Xcode is flashing, theSV9541will attempt anew ignition sequenceafter a fiveminutedelayperiod, if the call for heat is still present.Reset of the thermostatwill initiateanew ignition sequence immediately.

NOTE 2: Any combination of 5 �abnormal� events during a single call for heat will result in soft lockout. An �abnormal� event is a FlameSenseFailureDuringRun,AirflowProvingCircuitOpenDuringRun, or Limit CircuitOpenDuringRun. The flash codewill indicatewhichwas the last �abnormal� event that put the system into the soft lockout state based on the table above.

35440 01 2010 04

Typical Gas Valve HoneywellFigure 38

INLET

OUTLET

Diagnostic Light(on some models)

25--22--25a

On/OffSwitch

PilotAdjustment

ManifoldAdjustment(Hidden)

Manifold PressureAdjustment

INLET

OUTLET

25--22--49a

LO HI

36 440 01 2010 04

HONEYWELL SV9541Q �SMART VALVE� Sequence of OperationPOWER APPLIED TO APPLIANCE

THERMOSTAT CALLS FOR HEAT

COMBUSTION BLOWER DE--ENERGIZED

THREE SECOND FLAMEFAILURE RECYCLE DELAY

FIVE MINUTE WAIT PERIOD

PILOT LIGHTS AND FLAME IS SENSEDDURING 90 SECOND TRAIL FOR

IGNITION? (1)

PILOT VALVE CLOSES;PILOT IGNITOR OFF

FLAME SENSE LOST? PILOT AND MAIN VALVE CLOSE

COMBUSTION AIR BLOWER OFF AFTERPOST PURGE

FLAME SENSE LOST MORE THAN FIVETIMES IN THIS CALL FOR HEAT?

THERMOSTAT CALL FOR HEAT ENDS

PILOT AND MAIN VALVE CLOSE

CIRCULATING AIR FAN �OFF� AFTERDELAY

WAIT FOR NEXT CALL FOR HEAT

HI AND LOW AIR PROVINGSWITCHES PROVED OPEN?

NO

NO

NO

NO

YES

YES

WAIT FOR PRESSURE SWITCHES TO OPEN

(1) Ignitor turns �OFF� about 30 seconds into the trial for ignition. If the pilot flame hasnot lit, it turns back �ON� for the final 30 seconds of the 90 second trial for ignition.The pilot valve is energized during the entire trial for ignition. This is normal opera-tion for the gas ignition system.

(2) If a W2 call for heat is present, circulating fan on high speed. Combustion air blow-er and main valve remain on high.

NOTE: If main limit string opens and takes longer than 2 minutes to close, systemgoes into 1 hour wait period.

NO

COMBUSTION AIR BLOWERON HIGH SPEED

HI AND LOW AIR PROVING SWITCHESPROVED CLOSED WITHIN 30 SECONDS?

YES

PRE--PURGE

PILOT VALVE OPENS:IGNITOR POWERED

MAIN VALVE OPENS ON HIGH,IGNITER �OFF�

CIRCULATINGFAN �ON� ANDCOMBUSTION AIR BLOWER ON LOWSPEED. MAIN VALVE ON LOW FIRE

AFTER DELAY (2)

CIRCULATING AIR FAN OFFAFTER DELAY

COMBUSTION BLOWER �OFF� AFTERPOST PURGE

37440 01 2010 04

HONEYWELL SV9541Q �SMART VALVE� Trouble shootingThe 6 + X designation indicates a combination of flash codes: 6 flashes shows the control is in soft lockout, followed by X flashes to

indicate the reason the control went into soft lockout. Last status code indicates repair to address first

LEDSTATUS

INDICATES CHECK/REPAIR

Off No power to system control.Line voltage input at L1 and Neutral connectors on ST9162A Fan Timer.Low voltage (24V) power at 24 VAC and COM terminals on ST9162ASystem wiring harness is in good condition and securely connected.

HeartbeatBright � Dim

Normal indication whenever the system is powered, unless someabnormal event has occurred.

Not Applicable -- Normal Operation (stand by or call for heat)

2 Flashes

Low pressure switch closed when it should be open(i.e. when call for heat begins).(Combustion blower is not energized until pressure switchesopens)

Pressure switch stuck closed (system will wait for pressure switch to

open).

Pressure switch miswired or jumpered.

3 Flashes

Low pressure switch, open when it should be closed (i.e. longerthan 30 seconds after combustion blower/inducer is energized).

System goes into 5--minute delay period, with combustion blower/inducer off. At end of the 5--minute delay, another cyclewill begin.

Ignition system control switch must be in the ON position.

Pressure switch operation, tubing, and wiring.Restrictions in furnace air intake or vent piping.

4 Flashes

Main Limit or Roll Out Switch is open.

Combustion blower is energized, Circulating blower is energizedheat speed.

Main limit switch.

Manual reset burner rollout switch.

Limit and rollout switch wiring is in good condition and securelyconnected.

5 FlashesFlame signal sensed out of proper sequence.

Combustion blower is energized, Circulating blower is energizedheat speed after the �ON� delay.

Flame at pilot burner.

6 Flashes +1 Flash

Soft Lockout.

Failed to light pilot during 90 sec. trial for ignition

Combustion air blower is de--energized, Circulating blower is de--energized after the �OFF� delay.

After 5--minute delay time, control system will reset and initiate anew ignition sequence,

Gas supply off or pressure too low or high for appliance to operate.

Damaged or broken HIS elementLine voltage HOT lead wire not connected to L1 terminal on ST9162A.Furnace not properly earth grounded.Flame sense rod contaminated or in incorrect position.Pilot burner located in incorrect position.Pilot burner lead wires are in good condition and popery connected.Pressure switches operation, tubing, and wiring.

6 Flashes +2 Flashes

Soft Lockout.

Last failure was Flame Sense lost during run.

Maximum recycle count exceeded

Combustion air blower is de--energized, Circulating blower isde--energized after the �OFF� delay.


Gas supply off or pressure too low or high for appliance to operate.

Line voltage HOT lead wire not connected to L1 terminal on ST9162A.Furnace not properly earth grounded.Flame sense rod contaminated or in incorrect position.Pilot burner located in incorrect position.Pilot burner lead wires are in good condition and properly connected.Cycling, pressure switchCondensate drain blockedPressure switches operation, tubing, and wiring.

38 440 01 2010 04

HONEYWELL SV9541Q �SMART VALVE� Trouble shooting continued


Soft Lockout.

Last failure was pressure switch

Maximum recycle count exceeded

Combustion air blower is de--energized, Circulating blower is de--energized after the �OFF� delay.


Ignition system control switch must be in the ON position.

Pressure switches operation, tubing, and wiring.Restrictions in furnace air intake or vent piping.High winds blowing against vent.


Soft Lockout.

Last failure was limit circuit opened during run.

Combustion air blower is de--energized, Circulating blower isde--energized after the �OFF� delay.


Main limit switch.Limit and rollout switch wiring is in good condition and securelyconnected.Restriction in duct work.Dirty filter

7 Flashes

Soft Lockout.

Blower failure (typical)

Limit trip took longer than 2 minutes to reset.

System will start a new ignition sequence after 1 hour, if call forheat still present.

Dead blower.Blocked duct work.

8 Flashes

High Pressure closed when should be open. (i.e., when call forheat begins).(Combustion blower is not energized until pressure switchesopen)

Pressure switches stuck closed (system will wait for pressure switch toopen).

Pressure switch miswired or jumpered.

9 Flashes

High Pressure open when should be closed. (i.e., longer than 30seconds after combustion/inducer is energized).

Systemgoes into a 5minute delay periodwith combustion blower/inducer �OFF�. At end of the 5 minute delay another cycle begins.

Ignition system control switch must be in the �ON� position.

Pressure switch operation, tubing and wiring.

Restrictions in furnace air intake or vent piping.

39440 01 2010 04

11. Concentric TerminationVent Termination Clearances


Inlet and outlet pipes may NOT be venteddirectly above each other (standard ventterminals).


!

1. Determine termination locations basedon clearances spe-cified in following steps and as shown in Figure 7,Figure 39 through Figure 44.

2. The vent termination must be located at least 12� aboveground or normally expected snow accumulation levels.

3. Do NOT terminate over public walkways. Avoid areaswhere condensate may cause problems such as aboveplanters, patios, or adjacent to windows where steammaycause fogging.

4. Thevent terminationshall be locatedat least 4�horizontallyfrom any electric meter, gas meter, gas regulator, and anyrelief equipment. These distances apply ONLY to U.S.installations.

5. The vent termination is to be located at least 3� above anyforced air inlet located within 10� ; and at least 10� from acombustionair intakeof anotherappliance, exceptanotherdirect vent furnace intake.

6. In Canada, the Canadian Fuel Gas Code takes prece-dence over the preceding termination instructions.

Concentric Vent Termination - Kit #NAHA001CV & NAHA002CV

Thesekits are for vertical or horizontal terminationof the combus-tion air inlet and the exhaust vent pipes on Category IV gas--firedcondensing furnaces. The NAHA001CV kit can be used for 3� di-ameter pipe systems. The NAHA002CV kit can be used for 2�diameter pipe system. Refer to Table 9 for the correct pipe sizefor the furnace.Both thecombustion air inlet and the exhaust ventpipes must attach to the termination kit. The termination kit mustterminate outside the structure and must be installed per theinstructions outlined below for vertical or horizontal termination.Vertical termination is preferred. Field supplied pipe and fittingsare required to complete the installation.

2 or 21/2� Dia.SDR--26 Pipe

Kit Components

Kit Contents:3� Rain Cap or 2� Rain Cap3� Diameter SDR--26 Pipe, 191/2� Long or4� Diameter SDR--26 Pipe, 371/8� Long,2� Diameter SDR--26 Pipe, 315/8� Long or21/2� Diameter SDR--26 Pipe, 24� Long,3� Y Concentric Fitting or 2� Y Concentric Fitting

2� or 3� Dia.Rain Cap

3� or 4� Dia.SDR--26 Pipe

2� or 3� Dia.Y Concentric Fitting

25--22--03

Figure 39

Vertical & Horizontal Termination1. Determine the pipe diameters required for the installation

from Table 9 and Figure 41.

2. Determine the best location for the termination kit. SeeFigure 40 for vertical termination or Figure 40 andFigure 44 for horizontal termination. Roof termination ispreferred since it is less susceptible to damage, has re-duced intake contaminants and less visible vent vapor. Forside wall termination, consideration should be given to: 1)possible damage from the vapors to plants/shrubs, otherequipment and building materials, 2) possible damage tothe terminal from foreign objects, 3) wind effects that maycause recirculation of flue products, debris or light snowand 4) visible vent vapor.

Maintain 12� min. clearanceabove highest anticipatedsnow level. Max. of 24�above roof.

CombustionAir

Roof Boot/Flashing(Field Supplied)

CombustionAir

Vent

Concentric Vent Roof Installation

Vent

Support(Field Supplied)

45� Elbow(Field Supplied)

25--22--02

Note:Support must be field installed to secure termination kit to structure.

Figure 40

3. Cut one 5� diameter hole through the structure for theNAHA001CV Kit or one 4� diameter hole for theNAHA002CV Kit .

BPVC Intake/Combustion Air

Concentric Vent DimensionalDrawing

B PVCVent/Exhaust

D

A

11/2�

6�

25--22--03

C

Figure 41

40 440 01 2010 04

4. DimensionDmaybe lengthened to 60�max. or shortenedbycutting thepipes to12�min.DimensionAwill changeaccord-ing to D dimension. (See Figure 41)

Model A* B C D**NAHA002CV 333/8 2 31/2 167/8NAHA001CV 387/8 3 41/2 211/8* = Dimension will change accordingly as dimension D is

lengthened or shortened.**= Dimension D may be lengthened to 60� may also be short-ened

by cutting the pipes provided in the kit to 12� minimum

Table 9Concentric Termination Kit

NAHA001CV & NAHA002VC VentingTable Dual Piping ONLY

50,000 & 75,000 Btuh FurnaceNAHA002CV -- 35�� & (4) 90� elbows with 2� PVC pipe

100,000 & 125,000 Btuh FurnaceNAHA001CV -- 35� & (4) 90� elbows with 3� PVC pipe

1. Do not include the field supplied 45�elbow in the total elbowcount.

2. If more than four elbows are required, reduce the length ofboth the inlet and the exhaust pipes five feet for eachadditional elbow used.

3. Elbows are DWV long radius type for 2� and 3� vents.

If more than four elbows are required, reduce the length ofboth the inlet and exhaust pipes 5� for each additional elbowused.

*Feet of pipe iswhichever pipe run is the longest, either inletor outlet side.

If assembly needs to be extended to meet height or side wallthickness requirement, the two pipes supplied in the kit may bereplaced by using the same diameter solid, single (no couplingconnections) field supplied SDR--26 PVC (ASTM D2241) pipes.Do not extend dimension D more than 60�. (See Figure 41)

Do not use field supplied couplings to extend thepipes. Airflow restriction will occur and the furnacepressure switch may cause intermittent operation.

5. Partially assemble the concentric vent termination kit.Clean and cement the parts using the procedures for Join-ing Pipe and Fittings section of the manual. A) Cement theY Concentric fitting to the 4� diameter kit pipe. (SeeFigure 42)B) Cement the 3� rain cap to the 21/2� diameterkit part. (See Figure 42) NOTE: A field supplied stainlesssteel screwmay be used to secure the rain cap to the pipeinstead of cementing when field disassembly is desired forcleaning (See Figure 42)

Figure 42Rain Cap to Vent Pipe Assembly

Drill clearance hole in raincap and pilot hole in vent pipe.

Stainless steel screw(Field supplied)

25--22--02


When using the alternate screw assemblymethod, drill a clearance hole in the rain cap anda pilot hole in the vent pipe for the screw sizebeing used. Failure to drill adequate holes maycause cracking of the PVC components,allowing flue gases to be recirculated.Failure to follow this warning could result indeath, personal injury and/or property damage.

!


Do not operate the furnace with the rain capremoved as recirulation of the flue gases mayoccur. Water may also collect inside the largercombustion air pipe and flow to the burnerenclosure.Failure to follow this warning could result indeath, personal injury and/or property damage.

!

6. Install the Y concentric fitting and the pipe assemblythrough thestructure�s hole. For vertical termination, installthe parts through the field supplied roof boot/flashing.NOTE: Do not allow insulation or other materials to accu-mulate inside the pipe assembly when installing throughthe structure�s hole.

7. Secure the assembly to the structure as shown inFigure 40 or Figure 44 using field supplied metal strap-ping or equivalent material.

41440 01 2010 04

NOTE:Ensure the termination height is above the roof sur-face or anticipated snow level as shown in Figure 40 forvertical termination. Ensure the termination location clear-ancedimensionsareasshown inFigure 43andFigure 44for horizontal termination.

1� max.

Maintain 12� clearance above high-est anticipated snow level or gradewhichever is greater.

Figure 43Concentric Vent and Combustion--Air Side Termination

CombustionAir

Vent

25--22--02

12� min.

Roof Overhang CombustionAir

Vent

CombustionAir

Concentric Vent SidewallAttachment

Vent

45� Elbow(Field Supplied)

25--22--02

Strap(Field Supplied)

Flush to1� max.

Note:Securing strap must be field installed to prevent movement of ter-mination kit in side wall.

Figure 44

8. Install the rain capand the small diameter pipe assembly intheYconcentric fittingand the largepipeassembly.Ensurethat the small diameter pipe is bottomed out and securelycemented in the Y concentric fitting.

9. Cement the furnace combustion air and vent pipes to theconcentric vent termination assembly. See Figure 40 orFigure 44 for proper pipe attachment.

10. Operate the furnace throughoneheat cycle toensurecom-bustion air and vent pipes are properly connected to theconcentric termination connections.

Documents

*9MPT *9MPV - Carrier...Printed in U.S.A. LP1 9/4/2001 440 01 2010 04 2--Stage Gas Furnaces *9MPT-- Multispeed PSC Blower Motor *9MPV-- Variable Speed Motor *Denotes Brand MODEL NUMBER

9MPT 9MPV - Carrier...Printed in U.S.A. LP1 9/4/2001 440 01 2010 04 2--Stage Gas Furnaces 9MPT-- Multispeed PSC Blower Motor 9MPV-- Variable Speed Motor *Denotes Brand MODEL NUMBER